BUILDING A BOARD

I build very slowly. 

This has a lot to do with the dual nature of my HMS Terror project, which aims to create both an accurate model and a complete set of 1845 era plans. The latter has consumed hundreds of hours of my spare time and has led to some interesting side projects. It’s necessary and rewarding work, but it keeps me out of my workshop.  

Another reason I build so slowly is that I enjoy the process of building; figuring out the steps and making the templates and jigs to build accurately. My most recent sub-project was constructing a “building board,” essential for accurately aligning the bulkheads with the false keel of my model. The board needs to keep the false keel perfectly straight and perpendicular, while providing a flat surface for gluing the bulkheads at right angles to the keel.

I started the board by cutting a 1/4“ groove into a 32" long piece of MDF sheet. The groove is just slightly deeper than the false keel on the model, providing a full view of the rabbet, and fits tightly so that the keel remains perfectly straight.

Marking the groove on the MDF sheet. The board is 12" x 32 ". 

I cut the groove into the board with a table saw. MDF is brittle, so care is needed at this stage. 

The stern and stem of the model also needed to be kept perpendicular to the board. To achieve this, I designed two supports, one for the stern and one for the stem, which would slot into the building board groove.  I used a laser cutter to make these from 1/4” MDF sheet; they fit together somewhat like a piece of Ikea furniture.

My custom plans for the stem and stern supports. The idea for the interlocking pieces came from children's toys.  

Cutting the pieces from 1/4 " MDF. My local library provides a 60 watt laser cutter for public use. 

The pieces after cutting. 

The finished supports (stem on left, stern on right). 

It's hard to see, but the support has a rail designed to fit into the groove for proper alignment. 

The supports were glued into place, and their alignment was double-checked with a square. 

I lined the groove with painter's masking tape to prevent damage to the model's keel. 

I lined the supports with masking tape as well. 

The finished building board. 

Instead of using set screws, which might damage the model, I used rubber bands to secure the model in place. In practice
the fit was tight enough that rubber bands weren't really necessary. 

The bulkheads fit tightly and relatively squarely, but it was necessary to use a carpenter's square to
ensure that they were at perfect right angles to the keel. These stainless steel squares from Lee Valley
were perfect for the task.  

The second-to-last last bulkhead is put in place. 

The completed superstructure. It's hard to see here, but two of the forward stations have
alignment issues at the area of the chock channels and bulwarks and will need to be sanded and/or modified with
 trim.  I double checked the plans, and the errors, around 1.5 mm off, seem to have crept in from my
original measurements. These errors weren't large enough to force me to re-cut the stations. 

I'm quite happy with the alignment (the stern looks slightly twisted here, but it's just a trick caused
by the camera angle). 

Midships bulkheads at the position of the rabbet. 

A view of the bottom of the ship. Again, I'm quite pleased with the alignment
(the stem and stern are still little wobbly and will need some filling blocks). 

Mini-Crozer stands on his deck. It's been a long time.  

Mini-Crozier inspects the stern, noting that work is needed on the bearding line.
Though Terror was small by Royal Navy standards, a 102 foot ship was still a
substantial vessel, as this image indicates.  

Mini-Crozier stands at the Captain's sacred spot on the quarterdeck.  

Now that the bulkhead of the model is finally assembled, I can move towards planking it. A significant amount of fairing (sanding to ensure the fore and aft edges of the bulkheads match the ships lines) is necessary, and I hope to finish that shortly. Meanwhile, I've almost completed the "Phillips' Patent Capstan", and I hope to reveal my plans and model here soon. 

CREW ACCOMMODATION ON HMS TERROR

Inevitably, those interested in the history of the Franklin Expedition have pondered what it was like to live on the cramped quarters of HMS Terror and Erebus. As part of my goal to reconstruct lower deck plans for HMS Terror, I created cross sections and profiles for the great cabin, the captain’s and officer’s berths, and the galley stove. However, I also created plans for other areas of the lower deck and I think these better reveal what it was like for the crew aboard Terror during those long three years from 1845 to 1848. 

These plans use information contained in the original Admiralty draughts for HMS Terror and Erebus, with additional data gleaned from the plans for HMS Investigator. Further information was sourced from contemporary images of HMS Warrior, HMS Unicorn, and HMS Trincomalee, as well as several contemporary accommodation plans and models held at the National Maritime Museum. 

For further orientation, please consult my plans of Terror’s lower deck. 

A cross section of the crew mess area. Note the location of the large sail bin on the 
left of the section (only half is represented here).  Instead of benches or stools, 
the crew sat on their own chests, each shared by two men. The crew slept where
they ate - note the hammock hooks on the deck beam above the table. Each hook was 
spaced precisely 14 inches apart. 

Hypothetical arrangement of chests with available mess tables on Terror's starboard side. 

Precisely amidships, the warrant officers shared one cramped cabin. It had a very large chest of
drawers against the aft wall. 

The clerk in charge had a rather generous cabin with a sliding window, looking onto the
purser's steward. Such an arrangement was common, and presumably discouraged theft.
The mates had the smallest cabins on the ship - just large enough to accommodate the
standard furniture given to officers. 

Despite limited space, there were three storerooms on Terror's lower deck. The purser's steward
was located next to the clerk in charge's cabin, where he could keep a watchful eye on it.
It contained several bins and a chest of drawers. The captain steward and the gunroom
steward were outfitted identically and were located on opposite sides of the ship.
Each had a storage tank for liquids as well as chests of drawers. 

CANADA POST’S NEW EREBUS STAMP

Several months ago I mentioned on my blog that I was working on several side projects related to HMS Terror. Today, Canada Post unveiled a series of new stamps commemorating the Franklin Expedition and the 2014 discovery of HMS Erebus. The stamps include a permanent se-tenant issue and an international-rate stamp, and I was fortunate enough to have been asked to contribute an historically accurate plan to their design of the international stamp. I also provided comments and feedback on the ship depicted in the se-tenant stamp.   

The international-rate stamp showing the sonar image combined with
the upper deck plans. Image courtesy of Canada Post, used with permission. 

The international-rate stamp combines a modern sonar image with an upper deck plan of HMS Erebus that I created. The complete upper deck plan is featured on an uncut press sheet and I also produced a cross-section of Erebus that will be included in packaging materials. The deck plan shows HMS Erebus in her 1845 configuration, which no contemporary plan depicts. This new plan is based on ones I created for HMS Terror, which I carefully modified to accurately match the dimensions, fittings, and features of HMS Erebus.

The permanent se-tenant showing Erebus trapped in ice. Image
courtesy of Canada Post, used with permission. 

When I started creating plans of Franklin’s ships, I never expected that they would be seen by anyone but hobbyists and Franklin enthusiasts. I couldn’t have guessed that they might be used in a project such as this – especially juxtaposed with a real image of HMS Erebus. I was shocked at how accurately the plans matched the sonar image, which exposes much about the technology used on the search and the accuracy of the historical source materials relating to Erebus.

It was a thrill to work with the talented designers and professionals from Canada Post, and I’m very pleased with the result. These stamps are a must-have for collectors interested in the Franklin mystery and the discovery of HMS Erebus.

BUILDING HMS TERROR GIVEAWAY!

 Like HMS Terror? Like coffee or tea? This mug could be yours!

Today is the 202nd anniversary of Terror’s launch in Topsham, Devon, in 1813.

To celebrate, I’m giving away five coffee mugs printed with an accurate plan of Terror’s outboard profile, as she was fitted in 1845. I designed the plan and the mugs specifically for Terror’s birthday, and the giveaway is my way of thanking my readers for their comments, insight, and support.

Please note that I will not be selling the mugs; you will only be able to get one through the giveaway.

To enter, all you have to do is “share” one of my blog posts on public social media (Facebook, Twitter, Instagram, Pinterest, your personal blog, etc.), and provide proof to me that you’ve done so. And I’ve made it easy to share – simply click on your favorite post, and then go to the “Share it” section on the right side of the page. The five individuals with the most shares will each win a mug.

The plan used on the mug is similar to that shown in
last year’s Canadian Geographic Magazine.

The HMS Terror mug is Mini-Crozier approved!

Giveaway Details:

The giveaway item is one mug printed with an outboard profile plan of HMS Terror, as she was fitted in 1845. Only five mugs are available.

To enter, please “share” one of my blog posts on public social media (Facebook, Twitter, Instagram, Pinterest, blogs, forums, etc.). Paste evidence that you’ve shared (a link or screen capture) into an email and send it to me directly. Each time you share a post, you’ll receive one entry to the giveaway

“Shares” must be posted to public social media accounts (no private groups or websites, please).

The giveaway will run from June 29th, 2015 to July 13th, 2015. The five individuals who have the most “shares’ during this period will each receive a mug. In the case of a tie, winners will be selected randomly. Those receiving a mug will be notified on July 14th, 2015.

Mugs will be shipped on the week of July 20th by regular parcel post, to any address provided by the winner(s). Unfortunately, I cannot guarantee safe delivery of the mug; however, they will be thoroughly packaged, in a custom protective sleeve and box.

Best of luck, and I look forward to sending you a mug! If you are looking for content to share, why not try my most recent post?

Happy birthday to HMS Terror, and sincere thanks to everyone interested in her!

PULLING A RABBET FROM TERROR’S HAT

Last month, I finished the most angst-ridden part of my project to date - cutting two seemingly miniscule 1.5 mm wide grooves along the length of the keel and stem of my model. These v-shaped notches, known as rabbets, provide a seat for the edges of the hull planking where they meet the centreline timbers of the ship. On a plank and bulkhead model, it represents a critical reference point around which the hull architecture is based.  

My trepidation was rooted in the fact that the rabbet position isn’t shown in Terror’s 1836 draughts [1] (the 1839 draughts [2] only show the rabbet position for Erebus). Normally this wouldn’t be an issue, as Terror’s 1812 [3] profile plan clearly shows the position of the rabbet. However, the 1836 plans show that Terror’s bow, and in particular her upper deck and bulwarks, were extended forward approximately 12.5 inches (why this was necessary is still a mystery to me). This implied that her rabbet position must have been moved forward as well, to accommodate a smooth run of planking along the bow.

The rabbet carved into the model’s keel. Like the merchant ships which were the basis for Terror’s 
design, the 1812 draught shows the rabbet was taken out of the centre of the keel 
(incidentally, this position probably contributed to her poor sailing qualities).

I had originally assumed that Terror’s cant frames, hawse pieces, and bollard timbers may have been modified to accommodate this lengthening of the deck. This wasn’t an unwarranted assumption, because Terror’s 1836 profile plan shows that Terror’s upper stem piece was extensively remodeled, suggesting a significant refit of the bow timbers.

However, after further consideration, I’ve come to the conclusion that such extensive modifications were very unlikely. We know that Terror’s original top-timbers and bulwarks were entirely levelled when she was caught in a hurricane near Lisbon in 1828 [4]. This means that replacement bulwark stanchions needed to be installed when the ship was repaired. The upper deck may have been expanded at this time, but I suspect this occurred in the 1836 refit as the solid chock channels provided an opportunity (and platform) to most effectively hide this shift forward. In either case, because her bulwarks had been levelled, the modifications could have been made without extensive reworking of the bow timbers.

Therefore, my solution is to leave the rabbet position precisely as shown in Terror’s original 1812 draughts and to rely on modified bulwark stanchions to account for the lengthened deck. This permits me to move forward with the project with the least amount of conjecture, because the only speculation I need to make is about the construction of the most forward bulwark stanchions.

The port stem rabbet .

Another view of the rabbet - note how it "opens" slightly closer to the heel of
the stempost. 

A dummy section of planking dry-fitted into the rabbet, showing how it interacts
 with one of the station bulkheads. 

Settling on a final position of the rabbet allows me to finally assemble the bulkheads and begin planking the model. This decision also permitted me to finally draft a plan of Terror’s complete bow architecture.

Profile of the Terror’s bow architecture, showing the manner the bow was
strengthened for polar exploration service. To accommodate the
lengthening of the deck, I added a conjectural 12 inch chock fayed to
the fore edge of the bollard timbers and cant frames, against which
the bulwark stanchions would have been bolted.

Plan of Terror’s lower deck, detailing the layers of planking and
metal sheathing added to the ship

The plans expose the effort the Admiralty placed on strengthening the ship’s bow at the waterline. More than 55 inches (4.5 feet) of iron reinforced oak separated the stores on Terror’s orlop deck from the water. Near the foremast step, that distance multiplied to nearly 12 linear feet. James Clark Ross [5] tested these reinforcements in a most daring fashion during his Antarctic Expedition. By January 5th, 1841, Ross had spotted what he thought was open water south of the Ross Sea but found his way to it blocked by a ring of thick pack ice. Confident in his ships, he sailed along the barrier until he saw a “favourable point” and, under sail, rammed the Erebus and Terror into it for an hour, eventually fracturing the ice and punching his way through. He discovered the Ross Ice Shelf six days later.   

Footnotes:

[1] National Maritime Museum Object ID: ZAZ5672, ZAZ5663

[2] National Maritime Museum Object ID: ZAZ5673

[3] National Maritime Museum Object ID: ZAZ5615

[4] 1835. Narrative of the Wreck of H.M.S. Terror. United Service Journal and Naval and Military Magazine 1. Pages 229-236.

[5] Ross, Sir James Clark. 1847a. A Voyage of Discovery and Research in the Southern and Antarctic Regions, During the Years 1839-1843: Volume I. John Murray, London. Page 176.

LASER CUTTING TERROR’S BULKHEADS

I have arrived at the stage of my build where I am assembling the bulkheads that will give shape to the ship’s hull. I have already created bulkheads for this model using the traditional method – gluing the plans to plywood and cutting them out using a scroll saw. 

The old bulkheads - cut using a scroll saw (prior to sanding). 

However, I recently decided to change the way I will construct the bow of the model. I had originally modified the forward stations to account for the extra bolsters and planking at the bow, but I've recently decided to try to build these fittings (as a means to determine how Rice actually reinforced Terror against the ice). This necessitated rebuilding the two most forward station bulkheads. 

And this gave me an excuse for a whole new mini-project.

Following a current trend, my local public library recently opened a prototyping studio, which includes design software, 3D printers, and an Epilogue Mini 24 Laser Cutter. The library allows you to book the equipment for several hours each month - for free. I've wanted to experiment with a laser cutter for some time, and since I needed to make new bulkheads anyway, I decided to recut all of them. My hope was that it would result in a more accurate build.

The Epilogue Mini 24 Laser Cutter. The bed capacity is 12" x 24". 

The cutter works very much like a traditional printer and will engrave (raster) or cut (vector) based on the thickness of the lines shown in the image file (I used high resolution PDFs for this). My first attempt, using factory recommended settings, was somewhat of a disaster, resulting in charred and smoldering wood and unusable pieces (plywood is notoriously difficult to cut because of its inconsistent composition).

My first disastrous attempt. Note the burned and charred edges.

For my second attempt, I conducted some tests and determined the proper power settings needed to cut 5mm plywood with the thinnest, most accurate, cuts and a minimum of charring and burning [1].

As a test, I cut a series of discs with different power settings. 

The appearance of the cut edge with the proper settings (no charring). 

I engraved the station markings on each bulkhead.  The machine automatically engraves before cutting.

The bulkheads being cut. 

You can tell the cut was successful if the part drops away from the sheet. 

A finished sheet. 

Each bulkhead fits into slots on the false keel. 

The bulkheads slide snugly into place. 

Test assembly proceeds. This is just a dry -fit. 

The bulkheads dry-fitted in place. They need to be properly aligned, but I'm happy with the run already.
Mini-Crozier allows us to visualize how large Terror actually was (quite small for a Royal Navy vessel).  

A view from the bow.

This view shows the run of the ice channels very nicely. 

A top-side view from the stern. The bulkheads are just dry-fitted here and will need to be
aligned properly before gluing. 

I am very pleased with my experience using the laser cutter. The bulkheads are much more accurate than I could have produced by hand, and the process took about a tenth of the time normally required to cut and sand these parts. I will certainly be using it again when I need to cut more complex shapes and components for my build. 

Footnotes:

[1] For those interested, low speed, power, and PPI settings are a must, and the recommended wood settings for the Epilogue Laser will not work on plywood. Your goal should be a setting that will just barely cut completely through the wood, as this results in the thinnest cuts and edges that are browned, but not charred. My settings for good quality 5mm birch plywood were: Speed = 10, Power = 38, and PPI(Frequency) = 150.

HELPING TO BUILD A DIFFERENT KIND OF MODEL

Erebus drifts south in the ice, a still from Franklin's Lost Ships.
© Lion Television and 90^th Parallel Productions.
Image provided by Andrew Gregg, used with permission.

Last week, Lion Television, in collaboration with 90^th Parallel Productions, aired a wonderful new documentary, Franklin’s Lost Ships, on CBC’s The Nature of Things. The show was directed by Ben Finney and produced by Andrew Gregg for CBC, PBS, and Channel 4.

The documentary chronicles the 2014 Victoria Strait Expedition, culminating in the discovery of HMS Erebus by Parks Canada archaeologists and their collaborators. The film uses detailed computer graphics, historical reenactments, and interviews to bring the Franklin mystery into sharp focus - in ways we have never seen before.  

One of the most unique aspects of the documentary is the use of computer animations to bring Franklin’s ships, HMS Erebus and Terror, to life. I was fortunate to be asked to consult on the team’s attempt to recreate the ships and I have been corresponding with the producers since December of last year. I know that I wasn't the only researcher they consulted on the ships, so it was definitely a crowdsourced project.

Erebus and Terror push their way through the ice - a still from Franklin's Lost Ships.
© Lion Television and 90^th Parallel Productions.
Image provided by Andrew Gregg, used with permission.

Andrew Gregg, a producer for 90^th Parallel, oversaw the model construction process, which was undertaken by Redlab Digital, a Toronto-based visual effects studio. Mike Brown of Lion Television was also heavily involved, and Karen Kershaw led the artists at Redlab. The team’s goal, as stated to me, was to produce the most historically accurate reconstruction of the ships possible. My admittedly small role was to provide feedback and comments on the various drafts of the model build.

I sent Redlab copies of my plans and they consulted historical data such as paintings, drawings, contemporary ship models, and the original draughts of the ships. As they constructed the model, the artists would provide rendered images of different angles of the vessel to Andrew and Mike, who would then pass them on to me for comment. The process involved many drafts and I marked-up many images as, polygon by polygon, the ships began to take on a recognizable shape.

Until late February the ships were untextured grey geometric models, but I remember smiling broadly when Andrew emailed the first textured (fully coloured and detailed) render. Here was a complete view of one of Franklin’s ships, with the correct colour scheme and all of her unique systems, and I was thrilled to see it.

Fully textured render created by Redlab, showing a view of the hull of the ship. Note the iron bow plating.
© Lion Television and 90^th Parallel Productions.
Image provided by Andrew Gregg, used with permission.

Fully textured render created by Redlab, showing a view of the upper deck. Note the diagonal deck planking.
© Lion Television and 90^th Parallel Productions.
Image provided by Andrew Gregg, used with permission.

Fully textured render created by Redlab, showing the ship
covered in ice and snow.
© Lion Television and 90^th Parallel Productions.
Image provided by Andrew Gregg, used with permission.

Of course, readers of my blog know that I could never be fully satisfied with the accuracy of any model, and I worried that I would annoy Andrew and RedLab with all of my suggestions for changes. However, I learned quickly that they wanted to include every detail they possibly could, and they made changes to the models right up the last minute possible before their airdate.

Erebus and Terror sail again, a still from Franklin's Lost Ships.
© Lion Television and 90^th Parallel Productions.
Image provided by Andrew Gregg, used with permission.

Are there errors in the models? Sure there are. But these are relatively minor given the project and they are primarily because of time constraints. There are issues with the ice channels, the masts and rigging, and the various esoteric fittings bolted to the ship. But I suspect there are only a handful of people on the planet who could point out all of the specific issues (and most of them are currently diving on the Erebus).

I’m convinced that these are the most accurate models of Franklin’s ships ever committed to film, and I want to thank Andrew and Mike for involving me in their great project. I’ve spent the better part of two years trying to build a wooden model of HMS Terror, but I never thought I’d have the opportunity to see her sail in arctic waters again. Watching Erebus and Terror plough their way through the ice allows us to better comprehend the astonishing journey of these remarkable exploration vessels.

If you read my blog, don't miss this wonderful documentary.

Erebus takes advantage of her screw propeller. A still from Franklin's Lost Ships.
© Lion Television and 90^th Parallel Productions.
Image provided by Andrew Gregg, used with permission.

Acknowledgments: I would like to thank Andrew Gregg and Mike Brown for allowing me to post renders of the ships and stills from the documentary. It was a pleasure to work with them.