Assembly instructions
Valdivia
Order No.
1140
Stage 5, the deck
Part
Description
Material
Dimensions
No.
Note
No.
off
U
Base
Coated MDF
appr. 19x100x300
1
N.I.
W 1
Bending / gluing former
Spruce
Ready made
1
5.1
Deck girder
Spruce
2 x 7 x 150
4
5.2
Deck girder
Spruce
2 x 7 x 240
8
5.3
Deck girder
Spruce
2 x 7 x 260
4
5.4
Deck girder
Spruce
2 x 7 x 200
4
5.5
Deck
ABS, vac.
1.5
1
5.6
Screw
Brass
M2 x 10
14
5.7
Nut
Brass
M2
14
5.8
Mast socket
ABS, die-cut
1.5 x 26 x 50
2
Sheet B
5.9
Mast socket side panel
ABS, die-cut
1.5 x 15 x 50
4
Sheet B
5.10
Spacer strip
ABS section
4 x 4 x 50
4
5.11
Schooner mast
Alum. tube
12 Ø x 500
1
5.12
Mainmast
Alum. tube
12 Ø x 530
1
5.13
Spacer
Beech
5 Ø x 40
10
5.14
Battery retainer frame
ABS, die-cut
1.5 x 44 x 110
1
Sheet B
5.15
Channel reinforcement
ABS, die-cut
1.5 x 15 x 90
8
Sheet B
5.16
Channel
Alum. section
2 x 10 x 15 x 80
4
FS
5.17
Countersunk screw
Steel
2.2 x 9.5
8
FS
6
-
The purpose of the deck girders is to hold the deck in the
correct cambered shape, and this requires the use of a
special tool for assembling them. Apply a glue-resistant
tape (e.g. plastic packing tape) to the base U.
-
Apply tape to the cambered face of the tool W 1.
-
Screw the former W 1 to the base U. Mark the centre of the
curve.
-
Cut the four spruce strips to length for each of the five deck
girders 5.1 - 5.4. The four strips are laminated together in
a single process using ST-E.
-
Fix the centre of the strips to the former using a spring
clamp - Fig. 39
-
Fit a further four clamps, pressing the strips down against
the base - Fig. 40.
-
Mark the centre point on all the laminated strips. Leave the
glued girder to set hard for at least an hour before remo-
ving it from the former.
-
Repeat the whole procedure until you have made all five
deck girders.
-
Cut away the excess material round the edge of the deck
5.5 as described for the hull (“X” = “X”), and clean up the
edges carefully.
-
The next step is to cut out the hatch openings: drill 2 mm
Ø holes in the corners at the marked points and cut out the
hatched-in areas using a sharp knife or fretsaw. Sand the
cut edges - Fig. 41.
-
The fourteen 2 mm Ø holes along the outside flange are
used to position the deck and fix it to the hull. Drill the eigh-
teen 1.5 mm Ø holes at the marked points. Cut and file out
the two 12 mm Ø holes for the masts.
-
Drill five 3 mm Ø holes in the hatch coamings about 5 mm
above deck level; later the sheet guides are fitted in these
holes.
-
Cut out the notch in the point of the bow through which the
stem 1.4 / 1.5 fits - Fig. 42.
-
Mark the centreline on the underside of the deck. Place the
deck girders centrally between the hatch openings as
shown in Fig. 43, and centre them accurately. The forward
girder 5.1 should be located centrally below the small
hump in the deck - Fig. 44.
-
Trim the ends of the girders so that they finish 18 mm short
of the edges of the deck.
-
Glue the girders to the deck using ST-E. Clamp the ends to
the deck, and ensure that there is not a gap under the gir-
ders in the centre - Fig. 45.
-
Locate the 1.5 mm Ø holes in the deck over the girder 5.3
and continue them through the girder.
-
Place the deck on the hull, sliding the bow notch forward
until it rests snugly on the projecting stem - Fig. 46.
-
Line up the outside edges of hull and deck and clamp the
parts together using strong spring clamps as shown in Fig.
47. Locate the two forwardmost 2 mm Ø holes in the deck
and continue them through the hull, then screw the hull and
deck together using the screws and nuts 5.6 and 5.7.
Repeat this procedure with subsequent pairs of holes, wor-
king steadily aft - Fig. 47.
-
Cut off the excess deck material at the stern - Fig. 48.
-
Glue together the two mast sockets from parts 5.8 - 5.10 as
shown in Fig. 49, using SP-EX or ST-E. Check that the
masts are an easy sliding fit in the 12 mm Ø holes in the
mast sockets and the deck.
-
Place the mast socket assemblies over the ballast blocks.
-
To align the mast sockets place the model in the boatstand
with the bow touching a vertical wall; the wall forms a refe-
rence line for the alignment process - see Fig. 50.
-
Use a spirit level and two small wooden blocks of equal
height to ensure that the hull is exactly horizontal. Ensure
that the boat cannot slip or shift out of position - Fig. 51.
-
Slide the schooner mast 5.11 through the deck and into the
forward mast socket; at the bottom it should rest on the
bow ballast block 4.3. Set the mast at the angle shown in
Fig. 52 relative to the vertical reference line. When you are
satisfied, hold the mast socket in position using a strip of
