How to Build a Model Pirate Ship With Polyurethane Foam

Step-by-Step Guide

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   Step 1: Obtain sufficient polyurethane foam for your project.

   You should plan the size of your ship so you can calculate the amount of material you need, for the ship in the illustrations, 2 inch (5.1 cm) thick foam was used, and a piece of scrap 16 inches (40.6 cm) wide and 6 feet (1.8 m) long was used.
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   Step 2: Draw the basic shape of your pirate ship on a sheet of paper

   Add whatever details that need to be sculpted from the foam so they can be cut out, such as the prow, forecastle, main deck and aftercastle, if you want. , You don't have to be very accurate, since they can be shaped easily later using a sander, Surform plane, rasp, or even a fine-toothed handsaw. ,, You can pin the layers together with long wood screws to mark locations where you want to removed foam so the below decks will be hollow, and to create a space to install ballast which is needed if you plan to float your vessel. ,, Allow the joints to dry out and cure or to cool off so they hold the layers together firmly. , Rounding and tapering the sides toward the front and rear, and downward toward the keel will give your finished ship a nice shape. , You can cut these out so that they are hollow, or simple leave them as solid blocks, and you can also cut out individual steps in them with a sharp, thin-bladed knife if you like. , In each step of cutting and shaping the vessel, remember that balance is essential if you plan to sail the ship on water. , Holes can be punched into the foam with a piece of tubing by pushing and twisting it into the foam, or you can drill them with a power drill. , If you use brass tubing, you can heat it and push it into the foam so that they seal themselves, or you can drill holes for individual cannons with a drill. , This will protect the foam from the solvents contained in subsequent coatings of oil-based spray enamels if you use them, (otherwise, you can simply use a waterproof latex finish coat of your choice). , Using several light coats will usually give better results than applying a single, heavy coat. , Thin, dry, bamboo sticks work well, but balsa dowels, or even plastic straws or other materials will work.
   
   Add the number of masts you want, making sure they are centered on the ship, and build them as high as you like, keeping in mind they will greatly effect the balance of the vessel. , Add sails made from light, thin fabric to complete the ship's rigging. ,
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   Step 3: noting the length

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   Step 4: height

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   Step 5: and width so you can transfer these dimensions to the foam sheet.

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   Step 6: Mark the shapes of each layer on the foam sheet.

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   Step 7: Cut the top layer

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   Step 8: beveling the cut slightly as the next layer should be narrower

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   Step 9: since the sides of the ship should taper toward the bottom

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    Step 10: becoming narrower near the keel.

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    Step 11: Cut enough of these layers so that when they are laminated together

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    Step 12: they will give you the desired height of the ships hull.

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    Step 13: Remove any material you need to so you have a space for ballast

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    Step 14: if desired

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    Step 15: by hollowing out the middle layers of foam with a hand saw such as a drywall saw or a narrow trim saw

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    Step 16: as shown in the illustration.

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    Step 17: Check the fit of the layers

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    Step 18: then glue them together with a waterproof

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    Step 19: latex adhesive sealant

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    Step 20: or with a low-temp hot melt glue gun.

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    Step 21: Trim the exterior of the ship with a sander

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    Step 22: or other tool so the joints are flush and clean

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    Step 23: and trim enough so the sides of the ship are shaped the way you want them.

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    Step 24: Add blocks of foam at the fore and aft of the ship to create the raised stern and prow common on sailing sips.

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    Step 25: Shape your finished ship's hull by hand sanding the foam so that it is smooth and correctly shaped

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    Step 26: taking care to keep the opposite sides as symmetrical as possible.

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    Step 27: Make holes in the sides of the ship to accommodate the cannons.

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    Step 28: Build your cannons out of pieces of wooden dowels the desired diameter

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    Step 29: or use short links of brass tubing

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    Step 30: as shown in the photos.

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    Step 31: Coat all exposed surfaces of your ship with an adhesive latex caulking or a multipurpose latex primer.

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    Step 32: Spray the entire hull with a good quality enamel spray paint

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    Step 33: using the color you choose.

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    Step 34: Build your masts and rigging out of the lightest material you can find.

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    Step 35: Tie the yardarms and rigging to the masts with brown thread to simulate ropes

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    Step 36: gluing the knots to keep them secured with a plastic cement or hot melt glue.

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    Step 37: Add whatever details you want to your finished ship

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    Step 38: possibly including a crow's nest

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    Step 39: a rudder

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    Step 40: a skeg to the keel for balance

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    Step 41: portholes

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    Step 42: and others.

Detailed Guide

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