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Fighting Cog build instructions

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Fighting Cog build instructions

Build Instructions:

As always - if you intend to paint the model, you should paint all of the parts BEFORE assembly.  It's much easier that way.

Lower Deck parts:

First locate the lower deck, the two main beams and all of the "boot-shaped" hull side supports:

Glue the two main beams together, back to back and glue into the row of holes running across the center of the deck.  This is an intentionally tight fit.

Next glue all of the deck side supports into their holes.  There will be a lot of pressure put on these parts later (due to the curvature of the plywood deck sides) - so be sure to coat every contact surface of each part with glue for maximum adhesion:

The last two side supports have to be glued together - double-thickness for extra strength:

Next, locate the layers of the bow decking.  These are numbered for convenience.  Also find the two T-shaped pegs that help keep them aligned.

Starting with the (un-numbered) part with the planks etched on top - glue the two T-shaped pegs into the rectangular holes:

Then layer the part numbered 5, then 4, then 3, and finally 2 on top of that - putting plenty of glue between the layers and making sure that they are aligned symmetrically:

Finally - glue the entire assembly onto the bow end of the deck - the two protruding pegs should help with the alignment:

Next, locate the bow timbers and glue them back-to-back:

Glue that into the slot at the bow of the ship - push it all the way back into the slot - making sure that the "teeth" on the back edge engages with the layers of the bow part that we just finished putting together:

It's often useful to use some painters' tape (or masking tape) to hold things in place and to make sure that the head of the bow part doesn't come unstuck before the glue has set:

While that's all setting hard - let's build the rear fighting platform - locate the platform deck and the three cross-braces:

Glue the cross-braces underneath the deck:

Next locate the ornate pieces of the platform sides.  (You'll REALLY want to go crazy on painting these!)

Glue the two halves of the Saxon-cross together:

Glue three sides of the platform together...NOTE THAT THE ORNATE STERN PART IS AT THE END WHERE THE THREE CROSS-BRACES ARE!

Glue the rear part of the deck in place (oops! sorry - no photo of that step!)

Next, find the upper deck part and the parts of the bow and stern 'cabins':

Glue both together as follows:

Then glue both to the upper deck:

Locate the mast support parts:

Glue the smaller circular piec, then the larger square and then the smaller square to the top of the deck - making sure that the holes all line up perfectly (you might want to insert the mast dowel through the holes to be 100% sure!)

Then, glue the two remaining circular supports under the deck - and finish by gluing the solid circle on top of that...again, make sure all of the holes align perfectly:

Next, assemble the ladder:

Glue all of the steps into the holes in one side:

...then wiggle them into each of the holes on the other side:

Now comes the hard part!

The deck sides have to be curved - and the size of the plywood and the fact that they curve in two dimensions - means that there is quite a bit of force involved.

So we have to do this in two stages - first the front of the ship...then let the glue set for AT LEAST 6 hours...then we'll do the stern part:

Here are the two deck sides.  The end with the oval hole (which is for the steering oar) goes at the stern of the ship.

Slather PLENTY of glue on the sides of the bow section and the deck back to the first set of supports - and that first support 

Before you go any further, peel off about 8 foot-long strips of painters' tape (or masking tape) and stick them to the edge of your workdesk...you're going to feel like you need four hands for the next part...but so long as you use a slow-set glue that dries clear - you'll have plenty of time to fiddle with things to get them right...so try not to panic!

The idea is to get both sides of the ship glued to the sides of the fore-deck part - and to the bow post - then taped around with an unreasonably large amount of tape!  You need to be 100% sure that both parts are (a) touching the bow post and (b) sitting on top of the bottom deck part - on the little step formed by the deck part and the 5 layers of the fore-deck:

Be patient, take your time - but be sure that everything is lined up just right before you put the model aside for the glue to set...preferably overnight! DO NOT be tempted to try to bend the plywood along the sides of the ship at this point...if you do, it'll probably tear your tape and you'll have to start over!  It's going to look like the sides will never fit...but they will!

OK!  Welcome back!

Assuming the front part is still properly aligned - we'll go on to put glue all the way back to the stern of the ship - and on all of the support brackets.   Again, don't skimp on the glue - and have LOTS of painter's tape handy:

Now, bend the two sides all the way back - they'll curve both upwards and the sides will bulge outwards - but by the wonders of laser cutting (and lots of math!) IT WILL FIT!

Make sure that the sides are tight against all of those brackets and sitting up on top of the deck part.  Once you have it in place - wrap all the tape you have around the stern and the whole length of the ship.

Yeah - MORE TAPE!

OK - so let THAT dry for another 6 hours before going ahead with the next part and removing all of the tape.

You MAY find that you still have some small gaps - and you can squirt glue into those places to try to bring them together.

And now - you're almost done!  The fighting deck sits way back - with the three support brackets resting in the slots in the deck sides.  DO NOT GLUE IT IN PLACE!  (Or if you really must - don't to it YET!)

The stern of the ship now needs to be filled in with some planking.  Unfortunately, I've found that no two Cog kits that I've assembled have had the same gap at the stern.  The flexibility of the plywood, combined with the slight difficulty of getting everything PERFECTLY aligned means that the gap is different every time!

So to resolve this, the stern planking is made of three pieces:

Glue them together like this...but before the glue sets...

Put them into place and slide the two smaller parts outwards until there is a good fit against the ship sides - then glue in place.  More painter's tape and more waiting!

Finally, the mast and sail.  I advise gluing the main mast into the upper deck (which lifts off so you can game with figurines on the lower deck):

Lash the horizontal spar across the main mast using coarse thread - or (as I discovered) strip the insulation from some electrical wire - twist - and when painted, it looks just like very strong rope.  Wrap in a figure-8 around mast and spar amd apply lots of glue to hold it all firmly together.   The sail is looped over the horizontal spar and glued in place as shown:

ALL DONE!

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