Constructing the Fo'c'sle

The forecast, or fo’c’sle, of 15th & 16th century Spanish Naos is very unique, sets them apart and makes them easily recognizable. However, it also creates a very insteresting challenge for this build. 

I started out using a thin cardboard template to measure out what I would need to build. That way I could trim as necessary. The problem I ran into was getting the template stiff enough to sit in position while I put it together and made adjustments.

So I measured and created a wooden frame. I couldn’t get the slope of the bow right. Especially since I’d already planked my cardboard templates with the thin veneer walnut. Trying to trim the top where the deck would sit and sanding the super thin veneer glued to the thick paper was impossible! The walnut just kept splintering off no matter how subtle my sandpaper was. 

I was getting super frustrated. So I re-thought my plan, and started over.

I took the patterns that I’d already made, and used them to cut very thin plywood instead of cardboard. I took into account the errors in measurement I’d made before. That at least got me very close. 

My reformed idea was to cut the pieces, mount them, get everything to fit, THEN glue the clinker planks. That way I could use fingernail scissors to make adjustments at the tiny area where the deck and bow meet instead of sandpaper. 

I still needed to add a “brace” to get the pieces to stay in place and remain stable while I made final measurements and sanded the edges to fit perfectly. I used a piece of a sewing pin to lock that bar into place. 

I notched out the inside of the bulwarks for footing. This was necessary to get a nice even fit for the bottom of those thin walnut veneer pieces. Once the plywood was measured perfectly, adjusted, and mounted, I planked the entire thing with the walnut veneer. It’s important to note that I used CA glue (super glue) here because clamping each piece wasn’t very practical. Finally, I stained it all to match.

This is what the foredeck will look like once mounted in place permanently. This piece is only sitting in position at this point because I still need to find a way to mount the foremast and bowsprit.