How We Build Our Models
 Welcome, and thank you for stopping by the Handcrafted Model Ships workshop. Pull up a chair, sit down, and let me show you how we build our model ships. For many years, I have researched, designed and built model ships. Experience, patience, a strong attention to detail, and hundreds of hours are required to build the model ships we offer.
To build any model ship, there are five stages of production:
Showroom and Headquarters
Research
We take advantage of every available resource to insure that our models are authentic as possible.
Copies of the Mayflower plans |
HMS Victory in Portsmouth, England |
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Visit the actual ship (if possible)
November 8, 1997
the USS Constitution sailing in Boston Harbor |
Period paintings and drawings
We obtain copies of the ship's original plans (if available), artist's renditions, and drawings, or when possible pay a visit to the original ship (USS Constitution in Boston Harbor, HMS Victory in Portsmouth, England, USS Constellation in Baltimore Harbor and Cutty Sark in Greenwich Pier, to name a few).
Design
With our research complete, we use specialized software called CAD (Computer Aided Design) to draft a 3D image of the ship and a majority of the tiny wood pieces.
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| Rendering of the bulkheads and hull |
Rendering of the masts
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Renderings of the capstan and ladders
Layout of exactly how each knot should be tied |
Component Construction
| We use only the highest-quality woods available to make the various parts of each ship (cherry, birch, maple, blackwood, white lotus, walnut, rosewood, teak, yellow siris and light ebony, just to name a few). |
Racks of the various woods used to build the models |
| We make many of our pieces by hand; however, to reduce the time and cost required to make these pieces, our computer is attached to a laser cutter, which perfectly cuts the piece every time. |
Preparing the laser cutter to make gunport |
Laser saw cutting gunports |
Assembly
Once we have made the necessary pieces (over one thousand for a majority of our models), we start construction. We have a specialized production process with experts at each stage. This allows the models to be made faster, yet still meet our strict quality standards.
Let's walk through the construction process:
Hull and deck planking: This model is built using the plank-on-bulkhead construction method. This is a painstaking process that is the most time-consuming and most difficult part in building a model ship. If this process is done perfectly, the model looks as it should; if not done perfectly, the model looks obviously wrong. To build the hull, the following steps are taken:
1. The bulkheads are slotted over the keel (the ribbed frame of the hull). |
2. The individual wood planks are soaked in water so that they can be shaped around the bulkheads to conform to the hull. |
3. Each individual plank is perfectly shaped and glued to every bulkhead of the ship. |
4. Special-sized planks are cut and added to the hull, just like construction of the real vessel, to fill in any gaps between planked areas. |
5. A second layer of planking is applied over the primary planks to complete the hull. |
6. The hull is now sanded and layers of clear coating are applied to protect the wood. |
7. The gunports are cut out from the side of the hull according to the plans. After planking the hull, we carefully lay the deck planks and paint the hull the colors of the real ship. |
Details added: With the hull now complete, we add all of the details and fittings to the model (cannons, ship's wheel, stern details, figurehead, etc.) and the model is painted.
Masts, rigging and sails: Tremendous skill and patience is required to tie the hundreds of extremely small knots needed to complete the rigging.
Again, if this process is done perfectly, all of the lines are taut and there is equal tension on the masts. If not done perfectly, many lines will be loose and look obviously wrong. We use various colors and varied thickness to ensure the rigging lines are as accurate as possible. The masterfully stitched sails are made out of thick canvas (so that they will not wrinkle). We typically position the sails so the model will look as if it were at full sail.
Inspection
 Every stage of production is carefully overseen to insure the highest level of quality. Once a model meets our high quality standards, it is made available for sale. After an order is placed, each and every model is inspected before it is shipped to you.
Thank you for your time and letting me walk you through what is involved in creating these works of art. Please do not hesitate to call us if you have any questions, at (800) 313-9128.
Sincerely,
Richard Norris
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