What are CUTTING FILES & Assembly boat plans ?
We offer "Cutting
files and boat plans" for most of our kit boats. What does this mean ?
FROM CUTTING FILE CUSTOMER:
OPTION 1. Cutting files, assembly drawings, engineering boat plans. This option allows you to have the kit cut locally and this may be less expensive than a kit delivered from ourselves. Your location & other factors such the ability of the local cutting shop to undertake the bending and forming of parts that are part of the kit will have a bearing on your decision if a cutting files or option 2 ( KIT ) are best for you….See CUTTING FILES EXPLAINED BELOW
OPTION 2. Pre-cut KIT delivered to your location. This is our recommended choice of the low cost options as you will know that all the kit parts a perfectly cut and marked. All the formed and bent parts will have a perfect fit and we guarantee the kit to be complete and perfect in every way…. See KIT ASSEMBLY EXPLAINED
OPTION 3. Assembled Hull, Deck, Superstructure, Bulkheads, Engine beds & Rudder. This option will suit those that want to get off the mark as quickly as possible and still maintain a reasonable initial outlay at this stage. The H, D & S will be full prime-coated both inside and outside and all welds will be ground and touched ready for final painting. This option is ideal if you are located in an area where we have a recommended builder available to assemble the kit on your behalf.
OPTION 4. Hull, deck and superstructure with engine, steering, rudder and steering gear all fully installed and tested. Other items such as windows, ballast, bow and or stern thrusters, cabin soles etc. may be included in this package at your request.
OPTION 5. Turn key boat … This is a compete boat ready for you to take delivery and either sail or motor away on your first cruise. A nice option if you can afford it.
|Above is a set of parts cut and laid out as
they will be assembled into your hull deck and superstructure.
|This is the type of machine your local cutting shop will use to cut out your kit.|
CUTTING FILES LIST OF DRAWINGS ETC.
CUTTING FILES CAN BE NESTED TO A VARIETY OF SHEET SIZES.
Regards sheet sizes used to nest the cutting files. We are prepared to re-nest the parts on to smaller or larger or different size plates but the following should be kept in mind.
If the kits is cut from plates that are too small; a width of say 1200 mm / 4 ft is considered too narrow and for best results the plates should be at least 1.8 m / 6ft wide. Due to the enormous amount of extra welding involved, the chances of having a perfectly fair hull deck and superstructure will be greatly reduced if your kit is cut from narrow plates. The larger the sheet sizes used to cut the kits ... the smaller number of hull and deck plates ... the fairer the hull.
We have cut over 200 kits for sail and power boats ranging in size from 34 ft / 10.4 m to 85 ft / 26 m and in all cases the resulting plates avoided excessive welding and were easily handled using the minimum equipment.
In our cutting shops we use 6000 mm x 2000 / 19 ft 6 in x 6 ft - 6 in size sheets and occasionally 8000 mm x 2000 mm / 26 ft 3 ins x 6 ft - 6 in sized plate. We can of course re-nest these parts to shorter plates ( more cutting and welding ) but we feel that the width of the plates is even more important ... any plate under 2000 mm / 6 ft - 6 in in width will mean some hull plates have to be cut lengthwise; not recommended because of excessive welding which will adversely effect the final appearance of the hull.
If the larger plates cost more then the extra expense is justified when considering the reasons outlined above.
If in doubt, let us know what plate sizes are available locally, try more than one supplier for quotes and most importantly, DO try and obtain pre-shot blasted and primed plates and profiles.
Finally make sure you get competitive quotations for both Bruce Roberts and more than one local cutting shop. The local cutting shop may need 'cutting and marking lengths' as this governs the cutting machine times for cutting a particular kit, Bruce Roberts can supply this information.
The DRAWINGS associated with a the CUTTING FILES are AutoCAD drawings. If you want to view the Auto-Cad files and do not have a recent version of AutoCAD then you will need to have the drawings printed out by our selves or your local service print center.
HOWEVER: When we supply the
Cutting files or the KIT Study boat plans on DOWNLOAD or on CD - YOU CHOOSE DOWNLOAD OR CD. . .
The Various calculations are on XL files so you would need access to MS-XL to read these files or if necessary you have prints made by ourselves or your local print center.
The list below represents what is supplied for the Voyager 495-2 A cutting file set, but is also typical of what is included in ALL of the sets of cutting files for other kits.
Voyager 495-2 A Final Release AutoCAD Drawings
SHEET 1A Sail plan including sail measurements, Deck plan, deck fitting layout, rigging plan with rigging sizes etc.
SHEET 1AA .Accommodation profile and accommodation plan with notes on arrangements.
SHEET 1BB .Alternative accommodation plan with Accommodation profile and accommodation plan with notes on arrangements.
SHEET 1AAA .Additional detail on deck layout with details of deck equipment and fittings required and suggested layout.
SHEET 1AAAA .Detailed accommodation plan in both plan and profile with measurements for the interior joinery etc.
SHEET 1 BBB .Alternate accommodation plan with detailed accommodation plan in both plan and profile with measurements for the interior joinery etc.
SHEET 2 . Lines plan with sections, profile with buttock lines and waterlines, plan view with waterlines, hydrostatic calculations shown.
SHEET 3 .Engine installation details including installation of fuel tanks, all shown in plan, profile and sectional view. Many explanatory notes included on this sheet.
SHEET 3A Engine room showing details of exhaust system, fuel system several sectional drawings showing all details of fuel tank sections, battery placement plus many notes included on this sheet.
SHEET 4 .Details of fuel tank construction including venting arrangements, inspection hatches also details of propeller tube and shaft, rudder shaft and bearing etc.
SHEET 5 . Details of chain plate construction, sizes, hole sizes for attaching correct size rigging screws, and instructions for cutting to correct dimensions etc. Suggested method of installing chain plates.
SHEET 6 .Details of how to build the Bowsprit, assembly of rudder and construction of rudder bearings etc.
SHEET NEST PLOT These are the actual cutting files that are given to the cutting shop.
SHEET 2A-03 Bulkhead detail showing stiffeners and cut-outs and extra frame details
SHEET 2A-05 NEST PLOT Expanded and forming information for the radius plates
SHEET 2A 02 (1) Shows the layout of the various parts of the kit in exploded form, each part is numbered and shown in its correct location on the boat .all in PLAN view
SHEET 2A 02 (2) Shows the layout of the various parts of the kit in exploded form, each part is numbered and shown in its correct location on the boat .all in PROFILE view
SHEET 2A 02 (3) Shows each frame separately with measurements and layout of the numbered parts that go towards assembling each frame.
SHEET 2A 02 (6) Complete welding schedule for all parts of the boat. Each weld is shown in graphic form so all can understand the exact weld required.
1 booklet of written assembly instructions
1 set of kit assembly photographs (.jpg) format
4 sets of XL files
MTO Plate and profile list
Cut parts list with numbers
Sail plan dimensions
Spar calculations and detail.
The above list represents what consists of a SET OF
The above list represents what consists of a SET OF CUTTING FILES
PLUS: You will receive a BONUS DOWNLOAD or on CD - YOU CHOOSE DOWNLOAD OR CD. . .
PLUS: You will receive a BONUS DOWNLOAD or on CD - YOU CHOOSE DOWNLOAD OR CD. . .
The STUDY boat plans show most of the above sheets of
drawings but do not include cutting files!
The STUDY boat plans show most of the above sheets of drawings but do not include cutting files!
PREPARATION OF CUTTING FILES: Many of you may be surprised that it is not possible to take a regular boat plan even one that is already prepared using the latest computer aided design techniques, and use it for automatic computer controlled cutting. There are many steps between creating the original design and having the boat cut out on a computerized plasma-oxygen cutter. If a particular design is destined to be available as a pre-cut steel or aluminum hull, deck and superstructure package then this should be decided at an early stage in the design program. Some designs can be converted but it is preferable to start with automatic cutting in mind.
The main steps in preparing a new design for a boat that is destined to be cut out by a computerized plasma-oxygen cutter is as follows. Firstly it is usually the customer who gets the process started by contacting the designer with a brief outline of what they have in mind. Further correspondence quickly establishes the clients wish list. The list usually includes things such as type and style of boat, intended usage, overall length and beam. Draft limitations should be specified at this stage.
Accommodation requirements, number of regular crew as opposed to occasional guests should be stated. Speed requirements are important as are the clients attitude to fuel costs. This list may need some refining as some elements may conflict one with the other. It is part of the designers brief to ensure that the client ends up with a boat that meets most if not all their desires and overall requirements.
So far the process is very similar to what would be followed no matter from which material or building method was to be used to construct the vessel.
The next step is that the client and designer enter into a (in our own case) simple agreement where the designer agrees to prepare preliminary boat plans for the proposed vessel for a reasonable (a relative term!) fee. In our office we consider that the lines plan, general arrangement drawings consisting of exterior profile, deck plan, accommodation profile and plan views plus sufficient calculations to ensure that the final design can meet the clients requirements, constitutes a Preliminary plan.
Before a preliminary plan can be produced it is necessary to produce a 3D computer generated model of at least the hull of the vessel. Once the preliminary boat plans are completed and both the designer and the client are satisfied with the overall concept and layout of the vessel then we can proceed to preparing the complete boat plans for the vessel.
For the design to move forward it is now necessary to complete the 3D computer model that would at this stage need to include all items such as hull including transom, keel and rudder, all decks, cockpits, complete superstructure, main interior bulkheads and any other features such as Flybridge, radar arch, exhaust stack. Special items such as transom steps and other similar features are all included in this model. Depending on the complexity of the design, this process can take between 500 and 600 design man hours.
From this model all of the salient hydrostatics such as detailed weight calculations to enable material requirements and final displacement to be calculated. This allows stability calculations to be made at this time. During this process fine-tuning of the model can be undertaken to make sure that the finished vessel will meet all the design requirements.
Once the 3D model is completed and checked, then copies of this model are provided to the specialized designers who prepare the final model that includes all the scantlings such as transverse and longditunal framing, sole bearers, deck beams and engine beds. This same team then separate out all the parts for the frames, stringers, engine beds, bulkheads, hull, deck and superstructure plating etc., and add notches to the frames and bulkheads before nesting the parts on plates.
The design team put the correct number on each item and also reference lines are drawn on each part to represent frame locations etc. The purpose of the numbers is to identify each part and the lines are used during the assembly process to locate frames and other structural members.
Next it is necessary to work out a path for the computerized plasma-oxygen cutting machine. The path is the point at which the cutter enters the plate and starts to cut the parts. In addition, the path has to determine which part is cut next and so forth. This is all necessary so that the parts are cut in the correct order. For instance, if a window has to be cut from a cabin side, then the window aperture must be cut before the larger cabin side part is cut otherwise any movement in the cabin side after cutting could cause the window to be cut in an incorrect location.
ASSEMBLY boat plans: The assembly boat plans we supply with the CUTTING FILES or KITS cover several sheets of drawings and include all the information that your will need to assemble you kit. Also included are several sheets of engineering drawings showing lay-out of your engine room, exhaust system, steering system, fuel and water thanks etc.
Depending on the complexity of the design, the process from design to cutting files and boat plans can take between 500 and 600 design man hours.