Build the USS CONSTITUTION the World’S Oldest Commissioned Naval Vessel Afloat 03 Build the USS CONSTITUTION Contents STAGE PAGE 17 Walls and Gun Mounts 39

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Build the USS CONSTITUTION The world’s oldest commissioned naval vessel afloat 03 Build the USS CONSTITUTION Contents STAGE PAGE 17 Walls and gun mounts 39

18 Walls and gun mounts 41

19 Walls and gun mounts 43

20 Walls and gun mounts 45

21 Walls and gun mounts 47

22 Stern reinforcements and nails 49

23 Walls and gun mounts 51

24 Grating strips, wooden strips and eyerings 53

25 Wooden strips and nails 55

26 Wooden strips and nails 57

27 Wooden strip, grating strips and a cannon 59

Editorial and design by Continuo Creative, 39-41 North Road, London N7 9DP. Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE. Published in the USA by De Agostini Publishing USA, Inc.,121 E. Calhoun Street, Woodstock, IL 60098 All rights reserved © 2017

Warning: Not suitable for children under the age of 14. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown. USS CONSTITUTION STAGE: 17 16C Once the reinforcements have dried, you can Walls and gun mounts move on to shaping the frame of the hull. You should prepare a few tools, such as the sanding blocks and files shown below.

C 1. Fore walls 2. Gun mounts

16D To create a sanding block; wrap a large 2 strip of wood in some sandpaper. D

16A Retrieve the reinforcement A fret (Stage 15). Mark the four pieces with A and B, as shown, then remove them from the fret and sand them smooth. B A 16E Start smoothing the sides of the frames, A moving the sanding block from bow to stern (arrow). This will remove any roughness and begin to create a smooth line for the planks. B

16B Place the two A B E reinforcements either side of the false keel between frames 9 and 10, and the two B A reinforcements between frames 10 and 11. B

9 10 11

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16F Smooth the stern area, F 16I This is how the reinforcements and frames at especially the reinforcements. the bow should look when shaped. Take care not to alter the curve of the frames. I

16G Use a half-round file to smooth the curved frames, and to remove the bottom of the reinforcements to match the shape of the frames (Step J). G

16H Take one of the walls and H hold it against the side of the frames. Slide the wall down the sides of the frames to check that the piece is in full contact with 16J This is how the reinforcements and frames at all of them. the stern should look when shaped.

K 16K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.

40 USS CONSTITUTION STAGE: 18 Walls and gun mounts 18C Once the wall is the correct shape and fit, press it against the port side of the spar deck and tops of the frames.

1. Midship walls C 2. Gun mounts

18A Retrieve the walls supplied A 18D Make sure that the wall is flush against the with Stage 17. Smooth the edges edge of the deck. of the two walls with sandpaper.

18E To attach the wall to the hull properly, you will need to use the nails. The best tool to use to apply the nails is the nail pusher, which has a hole in the end where you place the head of a nail. You then use the pusher to push the nail into the wood.

B 18B Before adding the walls, E test-fit them in place around the spar deck at the bow. You will need to shape these to a curve by submerging them in water and carefully bending them. Apply a small amount of glue to the highlighted contact areas.

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18F Fix the wall to each of the F I frames at the points indicated, by pushing a nail through the wall and into the frame.

18G If you find that pushing G 18I Glue the wall into place up against the side of the nails won’t get them in all the deck and the frames. the way, you may need to use a hammer to drive them in fully.

18J Secure the wall to the frames with nails, as before.

H 18H Prepare the other fore wall J to fit on the starboard side. Make sure that the cutouts are aligned on both sides.

K 18K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.

42 USS CONSTITUTION STAGE: 19 Walls and gun mounts C

1. Aft walls 2. Gun mounts

1 19C Place the wall up against the side of the deck, as shown.

19A Test-fit one of the midship A 19D Once the wall is in position, fix it in place walls (Stage 18) along the side with the nails. of the spar deck, aft of the fore wall.

19E Glue the second midship wall to the port side of the spar deck, as shown.

19B Apply glue to the contact B E points between the wall and the deck and frames.

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19F Nail the wall to the frames. 19I Now fix the other aft wall to the port side of the deck, behind the midship wall.

F I 1

G 19G Test-fit one of the aft walls 1 on the starboard side of the spar deck, aft of the midship wall, as shown.

19J Then secure the wall to the frames with nails.

H J

K 19H Glue the wall to the deck 19K This stage is now and then nail it into place. complete. Store any materials that you haven’t used, because they will be needed in future stages.

44 USS CONSTITUTION STAGE: 20 Walls and gun mounts C

1. Fore walls 2. Gun mounts

20C Take one of the A pieces and glue it over the 1 last gun port of a fore wall, aligning the inner edges of both.

20D Now take one of the B pieces and glue it onto the A piece.

D 2 B

20A Test-fit the fore wall from A this stage underneath the wall 1 fitted in Stage 18. Starting at frame 1, engage the tabs in the top with the corresponding cutouts in the wall above. Shape to fit around the frames. E

B 20B Remove two gun mount 2 components from the fret, and remove the centre from part A. Then smooth the pieces B with sandpaper.

20E As you can see here, the edges of the front A two gun ports sit very close to the frames (dotted lines). You will need to cut away part of the A pieces for them to fit here (see Step F). 45 USS CONSTITUTION

F 20H Apply glue to the points of H contact between the wall and frames, then fit the wall into position and nail it into place.

B A

20F Here you can see how the forward two gun mounts have been cut to fit around the frames. Glue gun mounts to the I rest of the gun ports of the wall.

20J When the second fore wall is ready, fix it to the port side of the hull.

G 20I Prepare the other fore wall, J following steps A-G and using one of the previously received gun mount tabs.

20G Test-fit the wall into place, K 20K This stage is now with the gun mounts fitted. complete. Store any materials You may need to reshape some that you haven’t used, because of the mounts to fit with the they will be needed in frames (inset). future stages.

46 USS CONSTITUTION STAGE: 21 Walls and gun mounts C

1. Midship walls 2. Gun mounts

21C As with the fore walls, two of the midship gun ports are positioned very close to the frames, so you will need to adjust the mounts to fit.

21D Cut one side of the mounts off (dotted lines) to fit with the frames. D

21A Smooth both midship walls A 1 received with this stage. Test- fit the walls on either side of the hull, aft of the fore walls, as shown.

21E Glue mount A to the wall first, then the B piece over it. Make sure that the edge of the B piece is aligned with the cut side of the A piece.

21B Remove the A and B pieces B E from the fret and smooth with sandpaper. Glue the first A B piece over the forward gun port. Look at the following steps B before proceeding. A

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21F Test-fit the wall into position again, then I glue into place.

21I Secure the wall to the frames with nails.

21G Secure the wall to the G frames with nails.

21J Use a hammer to ensure the nails are in as deep as they can go.

H J

21H Test-fit the second K 21K This stage is now midship wall to the other side complete. Store any materials of the hull. Fit gun mounts to that you haven’t used, because the inside of the wall, following they will be needed in the process in Steps C and D, future stages. and then glue into place.

48 USS CONSTITUTION STAGE: 22 Stern reinforcements C and nails

1. Stern reinforcements 2. Nails A

22C Turn the hull over and test-fit reinforcement A in the slot in the false keel. Make any adjustments necessary, and glue into place.

22D Before the glue has dried, check that reinforcement A is positioned at a right angle to the false keel.

22A Remove the pieces from A 90° the fret and mark them with 1 their identifying letters. A B

C 22E Check that reinforcement A is positioned at a C right angle to frame 11 as well.

B 22B Once you have removed the E reinforcements, smooth them with sandpaper.

90°

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22F When reinforcement A is fixed in place, apply glue to the underside of it, as indicated here.

F 22I Apply glue to the I underside of reinforcement B.

22G Place reinforcement B G onto reinforcement A, sliding it into the slot in the false keel below.

22J Place the two reinforcements B C onto reinforcement B, as shown.

H J C C

90°

22H Make sure that K 22K This stage is now reinforcement B is fitted at a complete. Store any right angle to the false keel. materials that you haven’t used, because they will be needed in future stages.

50 USS CONSTITUTION STAGE: 23 Walls and gun mounts C

1. Aft walls 2. Gun mounts

23C Here you can see that the last two gun ports sit up against frames, so the gun mount will need to be shaped to fit. 23D Cut the mounts to the right size, then glue them into place.

23A Smooth the aft walls with A 1 sandpaper. Then test-fit one of them below the other aft wall, up against the midship wall.

23B Prepare the gun mount B pieces as before. Fit mounts over the first three gun ports.

23E Test-fit the wall into position again. Make any adjustments necessary and then glue into place.

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23F Fix the wall into position F I with nails.

23G Prepare the second aft G 23I Secure the wall to the wall following Steps A-D. frames with nails.

H 23J Use a hammer to ensure J that the nails are as deep as they can go.

23H Test-fit the wall in position K 23K This stage is now again, make any adjustments to complete. Store any materials the mounts as necessary, then that you haven’t used, because glue into place. they will be needed in future stages.

52 USS CONSTITUTION STAGE: 24 Grating strips, wooden strips C and eyerings

1. Grating strips 4. 2 x 2 x 300mm ramin strips 2. 2 x 4 x 300mm ramin strip 5. Eyerings 3. 2 x 3 x 300mm walnut strips

3 2 24C Once the grating is complete, apply instant adhesive to the joins between the strips.

4 24D When the glue has dried, cut a section of the grating 3 x 4 squares in size. 5 1 D

24A Position two of the grating A strips with the slots facing up, 1 then begin placing the slots of the other strips into the first two, as shown.

B 24B Continue combining the strips until you have a full square.

24E Smooth the edges of the 3 x 4-square section of grating with sandpaper.

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F 24H Smooth the surface of the H grating with sandpaper, and round off the top edges and the 3 corners. Paint the piece with clear lacquer.

24F Cut lengths of 2 x 3mm I 24I As with the decks, apply a walnut strip to fit the edges coat of stain to the grating. of the grating section – two short and two long, as shown. Glue them into place.

24J When dry, glue the grating 15mm forward of the foremast hole, as shown.

G J 4

15mm

24G When the glue is dry, cut K 24K This stage is now lengths of 2 x 2mm ramin strip complete. Store any materials to fit around the walnut from that you haven’t used, because the previous step. Glue they will be needed in into place. future stages.

54 USS CONSTITUTION STAGE: 25 C Wooden strips and nails 1 5

1. 2 x 5 x 300mm wooden strips 2. Nails

25C Place the strip onto the frames, pushed up against the bottom of the wall.

25A Take a 2 x 5mm wooden A 1 5 strip and hold it against the hull, up against the bottom edge of the walls. Shape it to fit from frame 5 forward to 25D Make sure that the aft end of the strip is frame 1. positioned halfway across frame 5.

25B Apply glue to the points of B contact on the frames.

25E Fix the strip to the frames with nails, starting at frame 5 and working forward to frame 1.

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25F When the glue has dried, F I cut the forward end of the strip flush with frame 1.

25G Prepare a length of G 25I Fit a nail to the join between the two strips, wooden strip to fit from frame 5 at frame 5. to frame 8.

25J Cut a third strip to fit from frame 8 to frame 11, then glue and nail it into place. Repeat Steps A-I on the other side of the hull.

H 5 J 8 8 11

25H Glue and nail the K 25K This stage is now prepared strip to frames 5-8 complete. Store any materials underneath the wall. that you haven’t used, because they will be needed in future stages.

56 USS CONSTITUTION STAGE: 26 Wooden strips and nails C

1. 2 x 5 x 300mm wooden strips 2. Nails

1 26C When dry, cut away the excess strip past frame 1.

D 4 7

26A Take one of the strips and A 4 shape it to fit from halfway 1 across frame 4 forward to frame 1. 26D Prepare a strip to fit from frame 4 to halfway across frame 7. Glue it up against the first strip from this stage and secure it with nails.

E 7 11

B 26B Glue the strip into place and secure to the frames with nails.

26E Complete the row by fixing another strip from frame 7 to frame 11.

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26F Fit another row of strips to the port side F of the frames. The first strip goes from frame 1 to frame 5, the second from frame 5 to frame 8, 1 5 8 11 and the third from frame 8 to frame 11.

G 26I When the ends of the I 11 strips end below the stern reinforcements, you will need to cut them flush with frame 11.

26G Here is how the aft end J 26J Repeat this stage on the of the strips should look when starboard side of the hull, so that fitted to frame 11. there are four rows on either side.

26K This stage is now 26H Fit another row below the complete. Store any materials others, starting and finishing that you haven’t used, at the frames indicated. because they will be needed in future stages.

H K

1 5 8 11

58 USS CONSTITUTION STAGE: 27 Wooden strip, grating strips C and a cannon

1. 2 x 4 x 300mm ramin strips 4. Carriage 2. Grating strips 5. Cannon 3. Carriage base 6. Cannon wedge 25mm

2 27C Cut two pieces of 2 x 3mm walnut strip to 1 25mm long and glue them to the sides, as shown.

3 D

4 5 6

27A Retrieve the grating from A Stage 24. Remove a section 3 x 6 squares in size. 27D Glue the third length from Step B between the ends of the strips from Step C.

27B Smooth the edges of the B grating piece. Then cut three pieces of 2 x 3mm walnut strip, each the same length as the long sides of the grating. Glue two to either side of the grating.

27E Retrieve the 2 x 2mm ramin strip (Stage 24), and cut four lengths to frame the outside of the grating assembly.

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27F Cut a 4 x 3-square section F out of the grating piece and smooth the edges.

27I When the glue has dried, use a small round file to curve the corners of the ramin strip between the two sections, as shown.

G I

27H Glue the two grating assemblies from this stage together in the way shown.

27G Cut and glue four lengths H J of 2 x 3mm walnut strip to fit around the grating piece. Then cut and glue lengths of 2 x 2mm ramin strip to fit around the two shorter sides and one long side.

K 27J Smooth the edges and corners of the assembly with sandpaper, then apply wood stain and a clear lacquer to it.

27K This stage is now complete. Store any materials that you haven’t used, because they will be needed in future stages.