The Mayflower has been designed as a
plank-on-bulkhead kit. Many of the ele-
ments have been laser cut for you and only
need some minor sanding before assembly.
Cut all of the laser cut elements free with a
sharp blade to avoid splitting them. Be
sure to sand any “burn” residue from the
part edges before applying any glue for
assembly.
To begin, remove the false keel (bulkhead
former) and lightly sand its edges. Glue a
1/16” x 1/8” basswood strip along the bot-
tom edge of the bulkhead former. See the
photos above. The bulkhead former is
3/16’ wide. When you glue this “rabbet
strip” along the bottom of the bulkhead
former be sure to leave an equal amount of
space on both sides of it. The rabbet that
is formed will help you while planking the
hull. An additional rabbet strip should be
glued to the stern post as shown in the sec-
ond photo above.
You will notice that there is a laser etched
reference for the bearding line at the stern.
This is also shown in that same photo.
The etched reference line only appears on
one side of the bulkhead former and you
will need to transfer this reference line to
the other side. The bulkhead former needs
to be tapered gradually from this bearding
line to the rabbet strip. Reduce the thick-
ness of the bulkhead former gradually to
3/32” wide. This means you will actually
be reducing the thickness of the rabbet
strip somewhat also. The bulkhead former
only needs to be tapered in the area
between the bearding line and the rabbet
strip. You do not need to taper the bulk-
head former forward of this area. Check
the tapered area on both sides of the bulk-
head former to ensure it is consistent.
Assembling the bulkheads…
Remove all the bulkheads and test fit them
in their respective slots on the bulkhead
former. Use the laser etched reference
lines under each slot of the bulkhead for-
mer as a guide. There are also etched ref-
erence lines on one side of each bulkhead.
All of the reference lines on the bulkheads
forward of the center line should face for-
ward. All the reference lines on the bulk-
heads aft of the center line should face the
stern. When satisfied with their fit you
can glue them permanently into position.
To complete this step glue the bow, fore
mast, main mast and mizzen mast fillers
into position. See the photos provided
GETTING STARTED
The two photos above show the rabbet strip glued to the bottom of the bulkhead former. The bulkhead former is tapered
from the bearding line to the rabbet strip.
Rabbet Strip
Rabbet Strip
Two fore mast fillers between bulkheads on port side.
Bulkheads in position at the bow
Bow filler
Taper to 3/32”
Bearding line
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Summary of Contents for Mayflower 1620
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