перевод
While waiting for the keel parts to be made and finishing the copper plating on Victory, I am slowly beginning work on Alert. To optimize workspace and improve efficiency, I have outlined a preparatory plan for the frames before assembling the keel and the building jig:
1. Cleaning – Removing sawdust left by the CNC router to minimize mess later.
2. Numbering – Marking each part with its respective number.
3. Sorting – Extracting and organizing each frame’s parts into separate bags for structured storage.
4. Trimming – Removing milling tabs and ensuring 90-degree angles in rounded router-cut corners. CONSTRUCTION:
5. Gluing – Assembling frame parts using dedicated jigs.
6. Sanding - removing glue and polishing the surface.
7. Shaping – Refining the frames to achieve the correct geometry.
8. Simulating bolts that join the frame parts.
Only after these steps will I proceed with assembling the keel and the building jig, where all these parts will be joined together.
The router left a lot of sawdust on the blanks, most of which I removed using a special vacuum nozzle.
Not a very difficult stage, but very important. In order to bring everything to maximum automation and conveyor, you need to prepare everything correctly.
I have already bought 100 zip-bags, in which I will group all the parts for each frame. But first, I need to pick out all these parts from the dies, and there are quite a few of them...
I am shocked myself, but today I completely extracted all the parts of all 85 pairs of frames and sorted them into prepared zip-bags.
Luckily, all the parts are available (there was even one spare) plus 14 additional pentagonal connecting parts.
I extracted them using a scalpel of this shape. By simply pressing along the grain, the holders were cut off. The only thing where there were very large holders, I had to cut them with a jigsaw.
85 zip bags and at least 4 times more parts.
After removing the parts from the molds, you must first remove all the holders so that the parts can be correctly inserted into the gluing templates.
But mostly the parts were held on 4-6 holders. They needed to be ground down to the correct geometry, as shown below.
By the way, the frames in the set consist not only of two parts, but also of 4, 6 and even 7!
So, we continue to prepare all 6 types of frames for gluing.
From the features, or rather from the flaws in the set! I thought that there were none, but still there were a couple, but it's good that they are not serious.
1. I thought that I had one extra part AL-61-3 (a fragment of a frame), but it turned out that AL-53-1 was also duplicated, BUT! No, what's worse, it turned out to be part AL-55-1. But, fortunately, it is completely the same as the extra AL-53-1, only shorter in the straight section, so I shortened it and replaced the number.
2. The second point is that these are different parts that should be the same. But, here too, I was lucky, because you can always make a smaller one from a larger one)))
1.5. Gluing – Assembling frame parts using dedicated jigs.
(1.6. Sanding - removing glue and polishing the surface).
To prevent the frames from sticking to the templates, you need to use cling film for insulation.
And here is the result:
In general, everything is very similar, but I did some things a little differently, so I will show you in detail again.
Spoiler: some of the rear frames had to be redone, because (if you remember, I showed this) there were defective parts and they had to be redone, but I will tell you about this in the next post, but for now...
Then, all the parts are taken out, a film is laid and they are assembled back, but with glue!
I polish with 240 grit sandpaper.
If you remember when I cut off the holders on the milled rams I noticed some parts with milled defects.
But we all know that PVA glue is a reversible glue, and if you heat it with an iron, it sticks out.
It was ridiculous when I almost made one part and then turned it over
and found that it had traces of a milling cutter right on the work
surface... had to be redone again =)))
The next in line are the one-piece frames of the central part of the hull...
Today I have already started to do them and it is much more difficult
and longer than what I have already done. There are more connections,
more frames, as many as 41 pieces and I understand that this is for a
long time))).
26.03.2025
Solid frames.
So,
before that there were paired frames, i.e. which consisted of a left
and a right half. I have already made 10 front ones (which needed to be
glued) and 14 rear ones, now let's move on to the 41st solid frame of
the middle part of the ship.
Of the 41 frames: 20 of one type and
21 of another, and each of these frames consists of 7 parts. And
accordingly, there will be many times more work on them...
But first, I needed to make one tool that would speed up the processing of one important unit.
First he gave the disc a perfect round shape...
By the way, the templates are connected with special clips that prevent them from changing the original geometry.
In total, in 2 days I made 4 full frames...
... and 8 halves of frames...... that in fact is 8 out of 41 frames and this is 20% of the total. So another 8 days of monotonous repetitive work awaits me... eh... let's go!02.04.2025
Moving on at a fairly good pace. I didn't count, but I definitely made more than half of the solid frames. When I finish, I will show you how to grind such horseshoe-shaped frames so as not to damage them. In the meantime, a couple of life hacks when working with templates.
The most obvious, but not always everyone does this (which leads to deformation when glued or glued to the steps in the glue seam). This is a fixation of glued fragments. The simplest method is to put the template on a perfectly flat surface, and put the load on the frames. In my case, these are dumbbell pancakes.
The second point is the clamps to maintain the correct (original) pattern geometry. So, there are only 9 of these latches. And if you glue the second parts of the frames, then only a maximum of 2 frames can be glued at a time. And in order not to wait until the glue dries and assemble on several templates at once (I do on 3-4 at once), these latches are not enough. Therefore, it is possible to glue ready-made fragments as they are manufactured and no longer use latches in this zone, but use them on new templates.As shown in the photo below: in the green oval there are already permanently glued fragments, and then in this area no latches are needed (shown by the red oval), and the latches can be used further (shown by the arrows). And those latches that are free - use on a new template.At this pace, I will soon finish gluing all the frames and you can start contouring them after grinding...
04.04.2025
To date, it remains to glue another 8 halves of frames, i.e. in fact 10%
of all 41 solid frames. Then grinding everyone and you can start
contouring those that are needed, there are about half of all 77 of
them. But it still feels that I am already at the finish of the first
chapter...
And another small life hack... so that very small edges of the workpiece
do not break off (especially if it is on wood fiber), you can glue with
cyanocrine that cist that can be chipped during processing.
05.04.2025
1.6. Grinding.
Hooray!... I finished gluing the one-piece frames together. There are 41
of them and a total of 65 frames that had to be glued together. And
this stage is over. I finished it 2 days earlier than expected. Now it
remains to grind them.
Frames that were halves I already showed how I polished out. Everything
is simple there. In a stacked template, everything is first ground on
one side. Turn, push and grind on the other side.
1.7. Shaping – Refining the frames to achieve the correct geometry.
To make it easier to bring the front and rear frames into the correct geometry, you need to give the most suitable shape. To do this, the set includes not only templates for gluing, but also templates for drawing lines along which grinding will take place.In the photo above, the 5th and 6th pairs of frames with their templates. There is an internal and external template. We must not forget that we do not make the same halves, but mirror ones! I.e. left half of the frame - mirror right!We lay the frame between two templates, fix it with clips and draw a line with a pencil.One moment... by patterns you need to cut the tips along certain lines, but I will not do this, but only draw these lines.And I will cut it when I adjust the frame under the body. So I will definitely not cut off too much and the connection will be tight. I saw this mistake from other masters that after the cut they had gaps in the joints.
The second point - I extended the length of the grinding zone by about 4 mm. In some frames, the cut point falls exactly at the end of the grinding zone. And in this place there may be processing defects, chips or grooves from the abrasive. Therefore, I raised the level a little so that the cut falls on a flat polished surface.
To limit the grinding zone, I made a wedge-shaped notch with a knife.
And so we have a grinding line, a notch on the edge, and now I draw a control line.
And now between these two lines I am grinding the frame, you can say cutting the angle. I do it with a portable engraver with such a nozzle.I recommend looking at such an angle that the working plane of the abrasive nozzle is parallel to these two lines.You need to try so that the grinder does not grind these lines, but only the wood (angle) between them. The control line is very important, since when working you clearly see the grinding boundary and do not remove too much!
Well, after I finish finishing the surface with a file. This is not necessary, since after assembly there will still be a general grinding of the case, but I still remove the rough scratch from the grinder and check the correctness of the geometry.
As a result, absolutely symmetrical halves of frames are obtained.These frames (4th, 5th, and 6th) without lock joints, but! According to the anatomy and even according to the manufacturer's instructions, they should be with them. But I understand that this element has been simplified. I did not want to add locking joints to these frames (this is long and not so easy), but I will make imitation of these joints using a simple method. The silhouette of the lock joint is cut with a knife to a shallow depth, polished and after covering with oil, the lines stand out and become like an adhesive seam.
Well, this is how real locking joints look before and after contouring and grinding.Another point. Some patterns are not the same length as the frames themselves...... therefore, these need to be positioned at the bottom edge in the corners, and see that the side contours coincide and if there is a line for cutting the tip too, so that everything matches there.Well, if there are any doubts about the accuracy of the positioning of the templates, it is better not to completely grind such frames, leaving excess for the formation of the profile after assembly. This will save you from geometry failures.
With solid frames, everything is almost the same, but for convenience I follow the following protocol.
First I apply an internal template, on one side, I draw a line...
... then I turn the same template over and draw an inner line on it on the other side of the frame.Then I turn over the frame and take the outer template and draw the outer lines...First, on the one hand, I turn over the template and draw the outer line on the other side of the frame.So it will be more difficult to get confused where to apply what.
All other stages are exactly the same as with halves. I have already done the front frames, the rear ones remain, and then you can start creating imitation bolts in the places of lock joints.
11.04.2025
Who else but me would notice the similarity of the frames with DNA? )))
12.04.2025
You can congratulate me, I have finally completed the preparation of all 85 sets of frames (and toptimbers).
And here I have a dilemma. Let's just say that I am very lazy, and I do not like to do something that will practically not be visible. Everything that is inside the case (provided that I will not cut it, but I will not sheathe it with slats either) practically after laying the deck beams will not be visible so as to make bolts inside. I don't have that much time, and I don't have that much desire either.... but outside... they will somehow be missed if they are not made. Drilling and inserting brass wire is definitely not for me. Yes, this is correct, beautiful and I take my hat off to those who do this, but again, there is no time or desire for this.
1.8. Simulating bolts that join the frame parts.
And I have a little option on how to do something similar to imitating bolts, but faster, and I'm interested in your opinion. I conducted small tests coating with tung oil on small fragments of frames. At the joints, I pierced the holes with a regular needle (diameter + - 0.4 mm), at the places where the bolts should be approximately. The puncture was done to a depth of + - 1 mm. And then he polished this place a little with fine sandpaper, filling this puncture with dust from grinding. And then he wiped it with a cloth, blew it and covered it with tung oil. The oil penetrated the injection site and visualized it. And the dust that remained inside the puncture did not make the injection hollow, and the oil sealed it. By the way, I tried to close the injection site with glue, but even without it, the result was exactly the same as with it, so I removed the extra action. The result is this.The photo does not convey the view that I see, but it is already clear that the dots are different from the frames, they will be simply visible without a hole in general view. Their location is only visual so far. And I remind you that the thickness of the frame is less than 4 mm! By the way, this is approximately what wood looks like without and under tung oil.
To be honest, I expected a little more from cherries. I understand that
this is not a pear, but there is a small ripple that wears a little. I'm
not even talking about the fact that there are a lot of different
colors in the set and in general I already expect a traffic light on the
model))) But for a skeleton it is even good, the details are separated
one from the other and there is something in this. The second body will
be made of pear. It is a pity that teak oil did not show itself as I
wanted, but before applying the oil I will definitely make probes and
give another chance to teak oil, if not, I will cover it, as I thought
it would. Regarding bitumen, this issue will be resolved only after the
same probes.
Well, what do you think about imitation bolts.
- to do,
- do, but only outside,
- not to do at all.
Well, when to do it? Now, while all the frames are in disassembly? Or
already on the model, which is more logical, since after the main
grinding you can walk with a needle, do everything and then finally
polish it together with imitation (punctures). But more inclined to the
second option...
13.04.2025
At the end of the chapter on frames, I want to add two more points.
The first moment concerns the first three pairs of frames.
According to the set instructions, they should be processed using
special template stickers. Which is convenient on the one hand, but I do
not recommend doing it right away.
The second point concerns the next 3 pairs of frames (4,5,6).
As shown in the drawing below...... The 4th, 5th and 6th pair of frames also have connections (i.e. do not consist of one fragment). This has already been implemented since the 7th pair. But interestingly, not only in the anatomy of this ship, these frames were prefabricated, but in the instructions for this kit, they also consist of 3 fragments (as shown in the image above). But for some reason, the manufacturer has simplified this knot, which can be corrected.Anyone who wants to repeat the real connection (as on the 7th pair) on all solid frames (4,5,6) (necessarily before contouring) can cut out a fragment (as shown on the 6th frame) and then paste the connecting fragment there. Yes - this is an extra action, for a long time, but it will be right, but!
Someone who is as lazy as I am can do an imitation of this compound as follows.
Oh yes! A very important point. I did not just arrange the connecting fragments in these specific places. Because (as shown in the drawing above) - these connections are located in certain places (as if in a checkerboard pattern). And in order to know exactly where their place is, it is better to do them at the moment of assembling the case. Assemble dry frames from the 7th and further and then applying the front frames to outline where the connections will be (as shown in the drawing above in the red circle).
So, how to simulate connections on the frames:First you need to attach the connector patch template and fix it...... then make the outline of this pattern with the blade. The thickness of the section and its depth are very important here. First, try to do it but the probe, below you will understand why.Then you need to lightly polish with sandpaper 240-320.
Well, here is the result after coating with tung oil:
And this is why you need to make probes of depth and width of the cut. Since with a large cut, it is visualized more than the glue seam and will be more noticeable, but...... if you choose the right depth and width of the section, you can completely achieve perfect similarity with the glue seam. But, there is also a consistency here. At the end of the post I will mention it, but for now I will tell you about the final version of imitation of bolts.
1.8. Bolt imitation (version 2.0)))
The first version with "punctures" for imitating bolts is a fairly fast and convenient way, but it has a slight disadvantage - punctures are a little more saturated than I would like and I will now show the second option, which I settled on.
It's still the same tool I used to make simulated nails on Victory's deck. Conventional helium pen. Three balls on very small sandpaper (1000-1500) until the ball falls out. And here's a ready-made cylindrical tool. To make such a round dent (injection), you need to lean the handle against the tree and gently press the top of the handle 360 degrees (the angle of inclination is small, up to 20 degrees). Or by pressing and twisting the handle around the axis. Depending on the density of the tree in different ways. The only thing is that the depth must be small otherwise either the tree will remain inside the handle, or the dent will be very saturated in color.I understand that this is not exactly an imitation of bolts, but most likely an imitation of pins, but I really like it. This is a quick and convenient way. And these punctures do not stand out as much, but they are also noticeable enough to create additional accents.
And as promised, I tell you in what order you need to do what:
The red oval shows the place to be made before assembly. Since these are interframe surfaces and after assembly they will no longer be accessible.
But what is shown by the green oval is that the surface (like the inner one) will be ground after assembly, and therefore imitation must be done after final grinding. Well, after imitation, you can already finally polish these places 320 with sandpaper very neatly and slightly.
Live, imitation bolts and connections look like in the last photo on the right. There is a relief and here about polishing, I still think, you may immediately need to cover with oil so that this relief is not sealed with dust from polishing.
Well, how do you like this result?
All, now, officially we can say that this is the end of the first part)))


































































































































