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Plank On Frame Construction - Replica Ship Assembly
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Call Toll Free: 877-258-2884
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Plank On Frame Construction
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Upon completing all of the required planks, frames and other
replica ship components, our builders then begin the replica ship
assembly process (The majority of our models are composed of over
one thousand pieces). Our specialized production process employs
experts at each stage to ensure strict quality control without
sacrificing efficiency.
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Hull and deck planking: This model is built using the plank-on-bulkhead (plank-on-frame)
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:
The bulkheads are slotted over the keel (the ribbed frame of the hull).
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The individual wood planks are soaked in water so that they can be shaped around the bulkheads to conform to the hull.
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Each individual plank is perfectly shaped and glued to every bulkhead of the ship.
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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.
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A second layer of planking is applied over the primary planks to complete the hull.
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The hull is now sanded and layers of clear coating are applied to protect the wood.
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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.
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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.
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Masts, rigging and sails: Tremendous skill and patience is required to tie the hundreds of extremely small knots needed to complete the rigging.
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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.
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