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
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
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 USB Memory Stick. - YOU CHOOSE DOWNLOAD OR USB
. . .
we do include all the drawings in
.PDF format ... PLUS we include a reader so you CAN view all the drawings on
your computer PLUS you can print them out on the PRINTER attached to YOUR
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
Sail plan including sail
measurements, Deck plan, deck fitting layout, rigging plan with rigging sizes etc.
.Accommodation profile and
accommodation plan with notes on arrangements.
.Alternative accommodation plan
with Accommodation profile and accommodation plan with notes on arrangements.
.Additional detail on deck layout
with details of deck equipment and fittings required and suggested layout.
.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
. Lines plan with sections, profile
with buttock lines and waterlines, plan view with waterlines, hydrostatic calculations
.Engine installation details including
installation of fuel tanks, all shown in plan, profile and sectional view. Many
explanatory notes included on this sheet.
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.
.Details of fuel tank construction
including venting arrangements, inspection hatches also details of propeller tube and
shaft, rudder shaft and bearing etc.
. 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.
.Details of how to build the Bowsprit,
assembly of rudder and construction of rudder bearings etc.
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
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
PLUS: You will receive a BONUS DOWNLOAD or on USB Memory Stick. - YOU CHOOSE DOWNLOAD OR USB
. . .
Sheet 13. Plumbing schematics.
Sheet 14. Exhaust systems.
Sheet 15. Tank construction.
Sheet 15. Anode sizes and placement.
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.
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.
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 loCATAMARANe frames and other structural members.
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.
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