Hull Modifications. General Introduction

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1 Hull Modifications General Introduction The living quarters for the Captain consisted of the Great Cabin, used for daily activities; Stateroom, used as sleeping quarters and the Coach Cabin, which in larger vessels was the cabin occupied by the Captain when an Admiral was onboard using the Captains facilities. For a smaller vessel like HMS Fly, the coach cabin was probably used by the Captain to eat meals with senior officers. The stateroom and the coach cabin are also cannon positions; therefore both cabins would have had cannon s. When not required, they would have been lashed to the bulkhead to prevent movement, and to give maximum space in the cabins. HMS Fly is a high quality kit, and this adaption to incorporate the Captains living quarters will demonstrate how scratch model building and model kit building can be successfully combined taking advantage of both skills. The objective will be to replicate everything in the Captains living quarters down to a flickering candle / lantern! Prior to working on the model kit, it is strongly suggested to use 5mm and 3mm foam board and thin card, to mock up the aft section of the vessel. Initially it can be difficult to visualise the changes that are required; but looking at a 3D model can make the task easier. Copy Parts 9, 10, 11, 12, 13, 14, 16, 23, 24, 114 and 146 from the original kit plans; you will also need approximately 290 mm of the aft section of the keel, Part 14. Using 3M Spray Mount stick and cut out the appropriate parts, then assemble, Figure D1. Figure D1 Foam board mock up of stern section Page 1 of 46

2 The aft section of the kit needs to be modified between bulkheads 10 and 13 so the Great Cabin, Stateroom and Coach Cabin can be incorporated in the space created, Figure D2. It could be questioned as to why this should be done, but the inside arrangements of each of these cabins can be viewed through the stern windows, aft side windows, two aft gun ports and the deck window lights, thereby adding realism; these notes will explain how this has been achieved. Figure D2 First rough mock-up A further mock-up of the completed hull was cut from 5mm ply and cardboard, Figure D3. This mock-up was built to ensure the modifications would work, prior to modifying the actual kit. It will also be used as the build progresses to test other modifications. Figure D3 Mock-up of complete hull with modified stern section To change the aft stern section, 1 X 4 mm Walnut strip was used; this was so the inside wood planking in the captain s cabin would be the same as the outer planked hull, Figure D4 illustrates a closer view, and shows the positioning of the cabins. Page 2 of 46

3 Figure D4 Modified stern section showing position of the cabins Modified Stern Section IMPORTANT NOTE: No responsibility can be taken for the advice given in these guidance notes. They have been written in good faith for fellow modellers who are looking to do something different and challenging. Please do not start this modification unless there is a clear understanding of how it is going to be achieved. This author found that making trial mockups was essential prior to modifying the actual kit. It is essential that the Stern Windows are unobstructed so a clear view can be had of the Great Cabin. Figure D5 shows that the maximum total width of 5 stern windows is 55mm. The internal width of the modified stern section, and that the end width of the stern deck is shown in Figure D6. The stern windows are positioned approximately 3mm below the stern deck, where the internal width is a little greater. This author achieved a width of 54mm; if an additional 0.5mm either side of the end stern windows is required, the sides of the Walnut strip fabricated stern section can be reduced in thickness. This can only be done once the hull construction has been added giving additional strength to this fabricated section. Page 3 of 46

4 Figure D5 Width of Stern Windows Figure D6 Illustrates the width required for the stern windows Page 4 of 46

5 The Keel, Part 22, was found to be slightly warped, so a metal keel clamp was constructed to ensure that it was held straight, Figures D7 & D8. Figure D7 Keel clamp Figure D8 Keel held in clamp to ensure that it is straight To maintain the exact external dimensions of the original kit in the stern area, modifications will need to be made to Part Nos. 12, 13, 23, 24 and 22, as shown in Figures D9, D10 and D11. Page 5 of 46

6 Figure D9 Modifications to Part No. 12 Figure D10 Modifications to Part No. 13 Page 6 of 46

7 Figure D11 Modifications to Part Nos. 23 and 24 To modify Parts 12, 13, 23 & 24 the craft drill was adapted to create a simple horizontal milling machine, Figure D12 & 13. This ensured that the wood was removed cleanly and at right angles, which would have been not so easy to have achieved with a craft saw. Figure D12 Craft drill adapted to act as a simple horizontal milling machine Page 7 of 46

8 Figure 13 Craft drill adapted to act as a simple horizontal milling machine Part Nos. 23, 24 & 13 had 1mm removed as illustrated in Figures D10 & D11. Figure D14 shows the 1mm being removed from Part No. 13. Figure D14 Wood being removed from Part No. 13 Part No. 12 was modified as shown in Diagram D9, but in this instance a smaller diameter grinding wheel was used, Figure D15. Page 8 of 46

9 Figure D15 Smaller diameter grinding wheel used to modify Part No. 12 Part No. 30, Quarter Deck has a 1 mm line drawn on it as shown in Figure D16. This is to enable Part Nos. 23 & 24 to be aligned to the Quarter Deck after having been modified. The 1 mm line is to compensate for the material removed. When the new stern section has been made it should then align with the Quarter Deck Part No. 30; to help align the stern section a centre line was drawn on the Quarter Deck. Figure D16 Part No. 30, Quarter Deck Page 9 of 46

10 Prior to the modification of Part Nos. 23, 24 & 13 the stern section was assembled and held with masking tape to understand how Part Nos. 23 & 24 should line up with the aft end of the Quarter Deck, Figure D17. Figure D17 Part Nos. 23 & 24 positioned prior to modification After modification, Part Nos. 23 & 24 were fitted into Part No. 13; ensure that Part No. 24 is positioned on the outside and Part No. 23 on the inside. To check Part Nos. 23 & Page 10 of 46

11 24 is positioned correctly they are placed on top of the Quarter Deck Part No. 30, Figure D18. Figure D18 Stern section aligned to the Quarter Deck Bulkhead, Part No. 12 was found to be a very tight fit into its keel slot; once the fabricated stern section has been built, it has to be removed from the keel. For this reason Part No. 12 was eased a little to ensure that it could be removed, Figure D19. Figure D19 Part No. 12 is eased into its keel slot Page 11 of 46

12 To ensure that it is perfectly square to the keel, card packing pieces were placed in the keel slot, Figure D20. Figure D20 Card placed behind bulkhead to ensure it is square When the bulkhead is fully inserted, its position is marked clearly on the keel, Figure D21. Figure D21 Position of bulkhead marked on both sides of keel Page 12 of 46

13 The following italic text is an Addendum, and the Figures are prefixed ADD/Figure E1 etc. and will not necessarily have continuity with the main text. The forecastle interior will be changed to incorporate a galley, and the heel and step of the bowsprit; to achieve this several parts of the keel will need to be removed, ADD/Figure E1; this is best done whilst the keel is flat. ADD/Figure E1 Section of keel removed for the forecastle interior Looking at ADD/Figure E2, it can be seen how the amended forecastle will look. ADD/Figure E2 Amended forecastle section Page 13 of 46

14 This author has planked the gun deck whilst it was fitted to the hull assembly, and during the planking it was found that there was a slight hollowing along the centre of the gun deck between bulkheads no. 5 to no. 9. This hollowing is less than 1/64 inch (0.4 mm), ADD/Figure E3, and perhaps it was caused by planking the gun deck on the hull assembly ADD/Figure E3 Slight hollowing along the centre of gun deck It is thought that this problem could have been overcome by modifying bulkhead no. 6, by inserting a small beam, similar to that used on bulkheads no. 2 and 4. A suggestion to correct this is shown in ADD/Figure E4, but whether it would resolve the problem this author could not say. ADD/Figure E4 Beam made to be used in bulkhead no. 6 Page 14 of 46

15 The keel modifications are drawn on both sides, according to Figure D22, D23 & D24. Figure D22 Modifications to keel Figure D23 Modification drawn on keel Figure D24 Modifications drawn on keel Page 15 of 46

16 Part Nos. 13, 23 & 24 are assembled and placed in position on the keel; the bulkhead is marked relative to the keel, Figure D25. The assembly is then temporarily fixed with spots of glue, Figure 26. Figure D25 Bulkhead marked relative to the keel Figure D26 Stern assembly temporarily fixed into position Page 16 of 46

17 Part No. 12 is positioned in slot ensuring that the card has been placed behind the bulkhead, Figure D27. This is also temporarily fixed into position with spots of glue, Figure D28. Figure D27 Part No. 12 Bulkhead, positioned into the keel slot with card Figure 28 Part No. 12 Bulkhead, temporarily held in position with spots of glue Page 17 of 46

18 This author found that Part No. 13, Stern Bulkhead was not square to the keel, but Part No. 12 was perfectly square to the keel, Figure 29. Figure D29 Checking that Part No. 12 Bulkhead, is square to the keel Adjustments will need to be made to Part Nos. 23 & 24 to ensure that all measurements are the same on both sides of the keel, Figure D30. Figure 30 Measurements of Part Nos. 23 & 24 should be equal on both sides of keel Page 18 of 46

19 The outside measurement of the stern must be constantly checked to achieve the maximum external dimension, Figure D31, yet will follow the 1mm line drawn on the Quarter Deck, Figure D32. Figure D31 Checking the outside measurement for the stern windows Figure D32 Checking the stern onto the Quarter Deck Page 19 of 46

20 To make the necessary adjustments to Part Nos. 23 & 24, this author used 0.5mm x 3mm and 1mm x 4mm Walnut strip, Figures D33 & D34. It must be stressed that every build will be different and this text should only be used as a guide. Figure D33 Adjustment made to stern Figure D34 Adjustments made to stern Page 20 of 46

21 Sticky tape is used to cover all of the surfaces, which are likely to receive glue from the fabrication of the stern section, Figure D35. Figure D35 Clear sticky tape is used to cover Part Nos. 12, 13, 23 & 2 Fabricated the sides first; start at the top and work downwards, Figure D36. Figure D36 Start on the sides first and work from the top to the bottom Page 21 of 46

22 Do not apply excessive amounts of adhesive, and from this author s experience, do not hurry this process and make sure each strip of Walnut is positioned correctly. Complete both sides of the stern section, Figure D37. Figure D37 Both sides of the stern section are complete Check that the Quarter Deck will fit the sides of the new stern section, Figure D38. Figure D38 Rear view of the stern section Page 22 of 46

23 Part Nos. 23 & 24 each has a flat edge, Figure D39 & D40. Figure D39 Flat edges on Part Nos. 23 & 24 Figure D40 Flat edges on Part Nos. 23 & 24 Page 23 of 46

24 This author found that the easiest way to fabricate the flat area of Part Nos. 23 & 24 was to use the stern windows as a template. Five Walnut strips 1mm X 4mm were fixed with adhesive and laid side by side; this made a flat piece of wood 20mm wide. A cardboard template was made of the stern windows and then laid centrally and squarely to the joins. The craft knife is held at approximately 45 degrees to cut out the curved section, Figure D41. Figure D41 Cutting out the curved section to be fitted on Part Nos. 23 & 24 The top and bottom parts that have the straight edges will be used, so do not discard them. The curved section is first fitted onto the flat edges of Part Nos. 23 & 24 and held in place with clear sticky tape. Make sure that this piece is positioned squarely relative to the top and bottom of the rear stern section that is being fabricated; i.e. the measurements on both sides should be equal from the top of Part Nos. 23 & 24, and equal from the bottom, Figure D42. Additional Walnut strips are added to the top and bottom to complete the stern section, and held into position with clear sticky tape, Figure D43. The curved top edge of the stern section is created following the Part Nos. 23 & 24, so creating the camber which the Quarter Deck will be placed upon, Figure D44. Page 24 of 46

25 Figure D42 Flat curved section to be fitted on the flat edges of Part Nos. 23 & 24 Figure D43 Walnut strips held in place with clear sticky tape Page 25 of 46

26 Figure D44 Clear sticky tape carefully removed after 24 hours from the stern section Once this section has been completed, allow at least 24 hours for the adhesive to fully dry before carefully removing all the clear sticky tape, Figure D44. Figure D45 illustrates a top view of the stern section, with clear sticky tape removed. Figure D45 Top view of stern section Page 26 of 46

27 The fabricated stern section is then gently prised from the keel. Providing the clear sticky tape was applied over all the wood surfaces exposed to glue, it will pull away very simply, Figure D46. Figure D46 Fabricated stern section To strengthen the corners of the fabricated section, two paper strips are soaked in adhesive and wrapped around the two corners; once dried it makes a very rigid reinforcement for the corner, Figure D47. Figure D47 Paper soaked in adhesive strengthens corners of stern fabrication Page 27 of 46

28 Excess adhesive is removed from the inside of the fabrication using a craft drill, rotary cutter/grinder and fine abrasive paper, Figure D48. Figure D48 Excess adhesive is removed Part Nos. 12 and 13 are removed from the keel. The forward facing side of Part No. 12 Bulkhead requires to be modified further, Figure D49; the reason for this is that firstly the inside of the cabin will be planked with Walnut strips, and secondly a 1mm space is required between the outside of the cabin Walnut strips and the inner side of Part 32 Gun Port Pattern; see also Page 41 for further details. This will enable the 1mm fibre optic cable from the lantern above the Captains table to be fed through to the base of the hull. Figure D49 Part No. 12 needs to be further modified on its forward facing side Page 28 of 46

29 Prior to modifying Part No. 12 Bulkhead, first remove the centre area as marked out in Figure D9. WARNING: During the cutting out of the centre section, it will need to be handled with great care. It will no longer be a solid piece of ply, especially when the centre area has been removed; the top layer of ply can also splinter on narrow areas, as this author found! Firstly use a fret saw to remove most of the ply; then finished with abrasive paper and needle files, Figure D50. Figure D50 Part No. 12 Bulkhead, centre area removed Abrasive paper fixed onto a lollipop stick with two sided sticky tape was found to be most useful, Figure D51, plus it can be easily changed. Figure D51 Abrasive paper fixed to a lollipop stick with two sided sticky tape Page 29 of 46

30 Following Figure D49; 1mm X 2mm recess is made in Part No. 12 Bulkhead, Figure D52. To ensure that the correct depth it will need to be raised depending upon the setup with the craft drill and grinder, Figure D52. Figure D52 1mm X 2mm recess made in the side of Part No. 12 Bulkhead Further modifications are required on Part No. 13 Bulkhead, as illustrated in Figure D53. Figure D53 Part No. 13 needs to be further modified Page 30 of 46

31 A redundant piece of 5mm ply from the kit Figure D54 is used to reduce the bulkhead slot for the keel. Figure D54 Redundant pieces of 5mm ply Following Figure D53, a piece of ply 8.5mm X 5mm is inserted into Part No. 13, Figure D55. Figure D55 8.5mm X 5mm ply inserted into the keel slot of Part No. 13 and glued Page 31 of 46

32 Following Figure D53, the Obeche is fitted to Part No. 13, Figure D56. Figure D56 Obeche is fitted to Part No. 13 It is important to ensure that the glue is completely dry, as it will be the ply insert and the Obeche which will hold together the separate halves of Part No. 13 when it is cut; for this reason it is suggested to leave for 24 hours. The section above the Obeche is then removed, Figure D57. Figure D57 The section above the Obeche is removed Page 32 of 46

33 The keel is cut along the red line as illustrated in Figures D22, D23 & D24. All the major modifications are now complete prior to assemble, Figure D58. Figure D58 The completed modifications prior to assembly Fibre Optic Cables (FOC) The exit point of the FOC s was determined by length of the FOC s used in the Candle Stand. These were approximately 280mm (11 inches), which meant that the FOC would have to exit at the rear of the hull. The finished model would normally be mounted on two columns Figure D59, as shown on the front of the kit box; a third column will be added for the FOC s to pass through. The keel together with Part Nos. 33 Prow, 34 Keel (forward), 35 Keel (Aft), 36 Rudder Post and 37 Rudder, were laid out flat, Figure D60. The horizontal distance between the end of the Rudder and the front of the Prow is 440mm; centre point is 220mm. One column is positioned centrally; the other two are positioned 150mm from the centre point. The position are all marked Figure D60, and it is important that Part Nos. 34 & 35 line up exactly with the main keel. Page 33 of 46

34 Figure D59 - Column Figure D60 Positioning of the columns on the keel To hold the model in place on the columns, 2mm stud bar will be used for the forward and centre columns. A simple jig was made with the craft drill to ensure that the holes were all drilled centrally in the keel, Figure D61. Figure D61 Drilling the holes for the column stud bar in the keel Page 34 of 46

35 A nut and washer are fitted in the keel for the forward and centre column holes, Figure D62. Figure D62 Nut and washer fitted into keel The nut and washer are fixed into the keel with an epoxy resin to ensure they will not move, Figure D63. Note: a little grease was put on the thread of the nut and screw to ensure that no epoxy resin would adhere to the metal. Figure D63 Epoxy resin used to fix nut and washer into the keel. Page 35 of 46

36 The hole in the keel for the FOC s is drilled 3mm diameter, and is shaped at the top so the FOC s can be threaded through from either side, Figure D64 & D65. Figure D64 Top of hole shaped in the keel for the FOC s Figure D65 Fibre Optic Cables threaded through keel (Testing) The corresponding holes are also drilled in Part Nos. 34 & 35 however; these are drilled just a little larger in diameter to accommodate any inaccuracies when gluing these parts to the keel. Page 36 of 46

37 The FOC s for the Oil Lamp, Candle Lantern s and Candle Stand are fitted prior to the hull being planked, so the FOC s will need not only to be protected during the build, but managed in such a way they do not interfere with the construction. This will be achieved by fitting a plastic tube below the keel. 5/32 inch plastic tube (4.00mm diameter) [StripStyrene Item No. 225, evergreen scale models Woodinville, WA 98072, USA] was used. The end was filed with a flat diamond file Figure D66, so it would be a firm fit into Part No. 35 Keel Aft, Figure D67. Figure D66 End of tube reduced in diameter using a flat diamond needle file Figure D67 End of plastic tube fitted into Part No. 35 Keel (Aft) Page 37 of 46

38 The plastic tube is bent at right angles; thin copper wire from an electrical cable was placed within the tube Figure D68, to help maintain its circular diameter when being bent. Figure D68 Copper wire used to prevent plastic tube kinking whilst being bent A hair drier is used to heat the plastic tube; it is then bent at right angles, Figure D69. Figure D69 Plastic tune bent using a hair drier The FOC s are threaded into plastic tube to check they will go in OK, Figure D70. Figure D70 FOC s are checked to confirm they can be threaded into bent plastic tube Page 38 of 46

39 The fixing of the plastic tube to the keel will be explained later in the notes. Assembly of modified stern parts Part No.12 is fitted into the keel, Figure D71; ensure that it lines up with the previously drawn reference points, and that it is facing in the correct direction forward/aft. Figure D71 Part No. 12 fitted into place Part No. 16 needs to be shortened, Figure D72, and then positioned Figure D73. Figure D72 Part No. 16 is modified to fit into position Page 39 of 46

40 Part No. 13 requires a little adjustment, Figure D73, and is then fitted Figure D74. Figure D73 Part No.13 is adjusted a little to fit into position Figure D74 Part No. 13 fitted into position Page 40 of 46

41 The fabricated stern section is positioned onto Part No. 12, and this should now be the same as when it was first being constructed on the original stern section before modification, Figure D44. It is initially held in position with masking tape whilst the glue dries, Figure D75, and then removed Figure D76. Figure D75 Stern fabrication being held in place with masking tape Figure D76 Masking tape removed from stern fabrication Page 41 of 46

42 Depending upon how the stern fabrication was constructed, it could be that there will be a small gap between the bottom of the fabrication and Part No. 13, Figure D77; this was filled, Figure D78. Figure D77 Gap between bottom of fabrication and Part No. 13. The gap between the stern fabrication and Part No. 13 is filled, Figure D78. Figure D78 Gap filled between stern fabrication and Part No. 13 Page 42 of 46

43 As mentioned on Page 26, Part Nos. 11, 10. 9, 8 & 38 will need to be modified to accept the Walnut planking on the inside of Part No. 32 Gun Port Pattern. Part No. 11 will have a 2mm recess one side and a 1mm recesses the other, Figure D79. Figure D79 2mm recess in the aft facing side of Part No. 11 Figure D80 1mm recess in the forward facing side of Part No. 11 Page 43 of 46

44 Part Nos. 10 and 9 are modified in the same way as shown in Figure D80, and Part No. 8 is only modified on the aft facing side. The cross beam for Part No. 8 is also modified, Figure D81; this is to ensure that it is not forgotten prior to placing into position. Figure D81 Part No. 38 crossbeam for Part No. 8 The route for the fibre optic cables needs to be determined, and then modifications made to Part No. 11 and the 5mm deck between bulkheads 3 to 11; (could not find part number) Figure D82. Figure D82 Modifications for the fibre optic cable route Page 44 of 46

45 NOTE: - Prior to assembling the bulkheads, the decision needs to be made as to whether they are partially bevelled on their edges that is required for hull planking. This author choose to do it after the hull assembly; An experienced modeller would have probably carried out the operations as described in, Preparing the Hull page 4 onwards, prior to assembling the hull. These are clearly explained in Simple Hull Planking Techniques for Beginners inners.pdf, pages 2 4. The hull is assembled, Figures D83 & D84. Figure D83 Stern section assembled with bulkheads etc. Page 45 of 46

46 Figure D84 View of assembly Lloyd Matthews May 2012 Page 46 of 46

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