Good afternoon everyone from a rainy and cold Nantong.
Well, it's been a week since my last post, so time for an update. As usual, thank you for all the kind words received so far and for following.
Phase 3 comprised of the installation of the gunwales, the construction of the cannon boxes and their corect placement on the gunwales. This was a task I was not looking forward to as it would see me try my hand at my first “plank-bending” exercise. And to add even more adrenalin was the fact that the “bending” was not only the normal bending that you would use when planking a hull, but also “vertical” bending. And true as Bob! The Batavia threw me its first curveball ... but more about that a bit later.
For the vertical bending part, I used the method as described by forum member, Glenn Barlow (Lady Nelson build), which, I must say, worked a cinch!. Thank you Glen! For the aspirant builders and newbies like myself, this just proves the value of being a forum member!
In a nutshell, I first immersed the planks in hot water for about a minute and thereafter laid it on its designated place on the full-scale plan. With the help of clamps or push pins (I used both methods, but the clamps work infinitely better) the wet plank is then shaped into its exact shape and curvature. After about 10 minutes, I “ironed” the planks with a steam iron. The steam worked well as it ensures that there is no scorching of the planks. While doing this, the planks visibly change colour as they become drier. Once done, leave the planks for another 10 minutes or so clamped and remove. Voila! You have a perfectly bent plank which can be glued immediately.
So with this successfully done, it now came down to the gunwales:
The instructions are very concise. Glue three 6mm x 1.5mm basswood planks on top of one another into their assigned slots provided for in the bulkheads. The slots in all bulkheads - except #13 - measures exactly 18mm which, of course, conforms to the added-up dimensions of the three 6mm planks. In the Dutch instructions it mentions that the planks “verspringen” at the stern which is translated in English as “the planks rise aft towards the stern”.
Unfortunately, this English translation falls short of explaining exactly what needs to be done, while the photographs in the instruction manual are not of great help. Even though I understand Dutch, I was unsure of the exact meaning of “verspringen” in this context and it took me a good few hours to figure out what was meant. The full scale drawings provided a good clue of what was meant, but even then, I still found it necessary to run my interpretation by some Dutch forum members first.
So, let’s see what is meant by “verspringen”. As usual, I will explain at the hand of some pics:
Above you will see that I mentioned the slots all measure 18mm except bulkhead 13 which measures 24mm. The idea is that a single and short plank is inserted from bulkhead #14 at the stern to bulkhead #13. The first and second full-length gunwale planks run from bulkhead #14 all the way and uninterrupted to bulkhead #3 at the stern. When it comes to the third gunwale plank, it starts its run from bulkhead #13 (not #14) and continues to the front to bulkhead #3. With that now understood, I inserted the short plank between bulkheads #14 & #13 and proceeded by gluing the first full-length gunwale plank into position.
Clamping process.
Full-length gunwale plank in position (view: port side). All good!
Second, full-length gunwale plank in position (starboard side). All good and very happy with there being no gaps between the two planks!
Third gunwale plank: CURVEBALL!!!
No matter how many times, I measured, the available space for the third plank was NOT 6mm - in fact, it was far less than that in some cases as small as 4mm. Sure I could plane the plank to 4mm, but I possess neither electric nor hand-planer and with 90% of all shops in China still closed because of the Coronavirus, I couldn't very well just go out and buy one. Trying to file or cut open the slots would result in too weak a joint between the bulkheads and deck beams and would also be negated by the height of the deck beams which prevented the planks from being slid higher up on the bulkheads. So I did the only thing I could think of. I glued a full-sized plank behind the first two gunwale planks to the maximum height it would go and made it run all the way from bulkhead #14 to #3 for maximum strength.
Obviously this means that the cannon port boxes will not sit flush all the way against the gunwales - there will be a 1.5mm (the thickness of the planks) gap between the back of the cannon boxes and the third plank, but there I will simply insert custom-cut pieces of planking as required. What I do have now are two gunwale sides that are immensely strong and solid being effectively double-planked.
Final gunwale in position - viewed from port side.
I must say, I am very happy with the angles as port and starboard sides follow an identical curvature. Also note in the above two photographs the extra bracing I have applied below the deck to the joints between the hull, bulkheads and deck.
Of course I contacted Hans from Kolderstok about the problem and he replied immediately. Hans commented as follows: "The nominal thickness of the walnut planks (which differ from supplier to supplier) may differ at times and affect the tolerances." He also said that he would incorporate the necessary changes to future kits where the slots will be enlarged to compensate for any variances.
Next up was the making of the cannon boxes - a fiddly and fidgety job, but one that I enjoy after all the headscratching with the gunwales. So far 13 have been completed - still 9 to go.
Cannon box parts are pictured next to a 1 Yuan coin for size comparison! When these are done, it will be time to measure out their exact positions on the gunwales, drill holes for the "push-in" cannons to fit and secure the gunboxes to the gunwales.
Thank you all for reading and following. This is all for now, I will be back - hopefully soon - with pictures of the installed cannons and gunboxes.
Kind regards-Heinrich