wefalck

The AEG got it´s teeth - hmmh, well - besides the painted on jaws I mean. The LMG 17/17 Parabellum are from Gaspatch, airbrushed satin black and then  I rubbed on steel pigments with a cotton swab. Stock and grip are painted with oil colors and after seeing the pictures, I decided to put on some varnish for a more realistic look. The kit guns are not bad and I used one inside the fuselage, but detail of the Gaspatch ones is absolutely fantastic. 
Positioning of the guns is not final. I also made some touch ups and detail painting and added the artificial horizon. 
Gun mounts and other details got sprayed aluminum, then covered with hairspray with the dark sea blue on top and finally weathered with a toothpick.

 
 

 

 
Cheers Rob

Looking good, the work!
 
Somehow I thought that the exhaust pipe(s) from the safety-valves are connect to those steam-relief pipes that are attached to ships' smoke-stacks. Unlike for railway- or traction-engines and the like, you cannot just let the steam off into the the (usually enclosed) engine-room. Do you have drawings of the prototype arrangements?

Ah, it's the 'Bobrik'. Here is a bibliography of this important mid-19th century German author of a very comprehensive maritime encyclopedia:
 
E   BOBRIK, E. (1846) Handbuch der praktischen Seefahrtskunde, Bd. I, enthaltend allgemeine Vorbereitungen zur Steuermanns- und Schifferkunde.- 1-816, Zürich/Hamburg (Julius Fröbel & Co./Hoffman & Campe).
 
E   BOBRIK, E. (1846) Handbuch der praktischen Seefahrtskunde, Bd. 2-1, enthaltend geographische und astronomische Steuermannskunde.- 817-1808, Zürich/Hamburg (Julius Fröbel & Co./Hoffman & Campe).
 
E   BOBRIK, E. (1846): Handbuch der praktischen Seefahrtskunde, Bd. 3, enthaltend logarithmische, geographische und astronomische Tabellen; Tafeln zur Schifferkunde; geometrische Zeichnungen, Abbildungen und Karten.- Tafeln (nicht ausgefaltet!), Zürich/Hamburg (Julius Fröbel & Co./Hoffman & Campe).
 
E   BOBRIK, E. (1848): Handbuch der praktischen Seefahrtskunde, Bd. 2-2, enthaltend Schifferkunde.- 1809-2688, Leipzig (Verlagsbureau).
 
B   BOBRIK, E. (1848): Handbuch der praktischen Seefahrtskunde, Bd. I.- 816 p., Leipzig (Verlagsbureau).
 
B   BOBRIK, E. (1848): Handbuch der praktischen Seefahrtskunde, Bd. II, I. Abtheilung.- 992 p., Leipzig (Verlagsbureau).
 
E   BOBRIK, E. (1848): Handbuch der praktischen Seefahrtskunde. Bd. II, II Abtheilung: Stereometrie ; Statik und Hydrostatik; Dynamik und Hydrodynamik; Schiffgebäudekunde; Zurüstungskunde; Manövrierkunde; Ankerkunde.- X+858 p., Leipzig (Verlagsbureau).
 
B   BOBRIK, E. (1848): Handbuch der praktischen Seefahrtskunde, Schiffgebäudekunde, Zurüstungskunde, Manövrierkunde, Ankerkunde, Tafeln zur Schifferkunde.- 604 p. + Tafelband, Leipzig (Nachdruck 1978 bei Horst Hamecher, Kassel).
 
B   BOBRIK, E. (1848): Vom Tauwerk und seiner Zubereitung zur Taakelasche (aus Handbuch der praktischen Seefahrtskunde.- 24 p., Leipzig (Nachdruck 1975 bei Verlag Egon Heinemann, Norderstedt).
 
E   BOBRIK, E. (1858): Allgemeines Nautisches Wörterbuch mit Sacherklärungen: Deutsch, Englisch, Französich, Spanisch, Portugiesisch, Italienisch, Schwedisch, Dänisch, Holländisch.- 752 p., Leipzig (Robert Hoffmann).
 
An E in front of the title means that you can find a digital version on the Internet.

I think the stand quite matches the somewhat improvised look of these boats.

The big bat flexes it´s wings. Today, I finished rigging the wings and I´m happy to have that behind me. It was not overly difficult on the outer wings, but fiddly with lots of scissors and tweezers involved, always adjusting the light and try not to knock off or scratch parts.

I loosely attached the rudder, but not the elevators. The tail will be last, as until now, it´s easy to set the plane onto some foam, bottom up. With about 60 cm of wingspan the bat starts to handle a bit awkward and it´s relatively heave, luckily quite robust.

It´s hard to see on the pics, but the white rudder has spar markings visible. I used 1mm masking tape over the spars, when I sprayed the tinted varnished over the whole airframe. 









Cheers Rob

Continuing the work on the pumps. First was the fabrication of the suction manifold for the condensate pump. This was followed by the dry fitting of the condensate system.

 
My soldering attempts.
 The finally dry fitted on site the suction piping to the condensate tank in the engine room. Need a little more work on the squareness of the pipe elbows.

Then the Mason boiler feed pump followed.

I have to say I love working the lathe. I am not as good as I used to be in my younger years but it is a pleasure to see the cuttings fall.
 
This are some of the parts.

Then the dry fit assembly

And the final product.
 

Thanks for following
 

I think the stand quite matches the somewhat improvised look of these boats.

@Harvey Golden Thanks! I may look into a base board. The stand is just stained basswood, so it wouldn't be hard to match, although I would probably have to pre-treat the board so the stain comes out evenly.
 
Well, I finally got the upper layers of the thatching on. The results are.... a bit mixed, I think.
 
As can be seen, I ended up doubling the upper support crosspiece so there would be more of a gluing surface to work with.

 
The very top will be covered with some cloth, which seems to be what was done on the actual vessels if I'm interpreting the photos correctly.

 
While I avoided the unnaturally straight edge I unintentionally gave my first attempt, I'm not totally happy with this one. As can be seen, the layers are each very thick. This wasn't a problem on my first attempt, as the layers were much thinner, but on this one it's very noticeable. While photos make it clear that plenty of actual canoas did have layered thatching, it never seemed to stick up so much like this.
 
From some angles, and from a distance, I don't think it looks bad.

 
But from others, it looks like a bad haircut.

 

 
So, I'm a bit torn about how to proceed. As I see it, I have a few options:
 
1) I could redo it with just a single layer so that I don't have to worry about any overlap, but that seems daunting. I've already spent months working on the rancho, and while I'm not on any timeline for completion, I would like to actually finish the build at some point, and I especially would like to be able to move on from the rancho into more interesting parts of the build.
 
2. I could redo it with a simple wood rancho. It would be a lot easier and faster, but I have to admit that I think it would be visually less interesting.
 
3. Leave it as it is, accept that I've done a lot on this already and have learned some lessons about considering how parts will come together while scratch-building, and hope that I one day come to love it, bad haircut and all.
 
4. Continue with it, but see if I can lesson the jarring transition between layers by sticking some additional individual pieces of straw into the gap, as I've started testing (without glue) below.

 

 
I think I'll try option 4 for at least a bit to see how it turns out. I don't think it's going to make the haircut look worse, at least.

I finally had a peaceful weekend and was able to advance!
 
First, I finished the base. I'm not crazy about it, as I think I made it slightly too long, and I feel like the color stands out too much. I may paint it black, or make a new one to a different design later. But for now, at least the model has a proper stand.

 

 
I also finally made some progress on the rancho! First, I superglued bits of wire into the holes I drilled in the base of the rancho supports. I think I need a new superglue, as the stuff I got is extremely tacky and seems to stick poorly. Meanwhile, I was progressing bit by bit on the upper layer of thatching.

 
As can be seen, I improved a lot at keeping the string more or less in line. Unlike the lower layer, where I added varnish after each bunch of thatching, for the upper layer I used a generous helping of glue from the string to the top as I went (it will be covered later) and have only added the varnish now at the end. Once that dries, it will be time to remove the thatching from the backing (index card laminated in tape so the glue doesn't really stick).
 
I also glued the lower layers in place on the rancho, using a lot of coffee stir sticks and scrap to clamp.

 
The lower layer is now on pretty solidly.

 
I'm looking forward to finally being done with the thatching, it's taken far longer than I had hoped. If something goes catastrophically wrong at this point, I'll probably just make a wooden rancho, which would be less interesting but equally accurate at far, far easier to make.

... and one shouldn't anyway now.
 
In principle, anyone with a good tool-grinder could make such tools from round HSS-blanks.

I am a great fan of Fowler traction engines, because of their looks and perhaps also because of their German connection: a young German engineer in search for better opportunities than on the continent ended up with Fowler in the 1860s. He made some important inventions/improvements to their ploughing engines, reorganised the Egyptian cotton industry with the help of Fowler engines and eventually became their agent for the German states and Eastern Europe with a seat in Magdeburg. 
Some 35 years ago, I built a Fowler Z7-type ploughing engine from a 1:76 Keil-Kraft kit (which at that time were readily available in model shops) with a lot of 'scratch'-building, as I had just acquired a watchmakers' lathe. The actual engine was virtually absent from the kit and various other aspects of the kit had to be corrected:

Before painting showing the amount of detail added to the Keil-Kraft kit.

Finished and painted Fowler class Z7 ploughing engine in 1:76 scale.
 
I was lucky to live in the UK at the time, so I could visit various steam-fairs to take pictures of originals and there was also a local museum that owned a class BB ploughing engine.
 
I didn't know that there was an 1:35 scale kit of a class B6 traction engine. I always wanted to build a model of those. The kit looks good, but it is a pity that the whole engine-block has been cast in one piece. I would want to make the metal parts from real metal ... does the kit come also with wheels with rubber tyres? This is the configuration as agricultural engine. Not sure what the army would have used. The agricultural wheels would give more traction 'off-road', but are rather uncomfortable to ride on paved roads.
 
Incidentally, the German army experimented with traction engines as artillery tractors in the 1870/71 Franco-German War. I believe they were Fowler engines. There are not many accounts of their performance in the published literature - military writers of the time mostly were no techno-freaks and quite conservative. While their pulling capacity was judged favourably, the logistics of supplying them with fuel and water became too difficult as they moved away from railway lines. One should read up how the British did this during the Boer Wars, where armoured traction engines were used.
 
Looking forward to the progress in this building log  😃

Well, it's back to the Gjøa again....  As I get close to the mast and rigging, I needed a good sturdy work stand for it-- one that will double as a display stand.  (The stand is 7/8" thick Southern Yellow Pine--a heavy and solid foundation).  The hull, as shown below, measures 27" long, and will be considerably longer once the stern davits and the bow sprit are on.  My workspace is only 45" long, hemmed in by a steel file cabinet, and a bookshelf, so this will be tight work.  I expect slow progress from now through the summer, but am aiming for an early '25 completion.  Welcome back!

 

The bottom of the model, seen from the inside .....

Once again, Thank You for your kind comments !
 

Again, real life including (business) travels got in the way of progress on this project. In addition, while I was having dinner in a restaurant together with colleagues, suddenly some ‘floaters’ appeared in one eye. I went immediately to the eye-doctor, who checked my eyes thoroughly. Luckily the floaters are harmless, but annoying signs of age. No retina-detachment or something else serious. Apparently, they can spontaneously disappear or the brain sort of ignores them after a while – keep fingers crossed. For the moment they are quite bothering, when working on really small things … so on to the ensign.
 
************************************
 
The Imperial German Navy Ensign

This ensign was first conceived for the navy of the North-German Alliance (Norddeutscher Bund) in 1867, bringing together the colours of the dominant powers, namely Prussia (black-white) and the Hanseatic City States, Hamburg, Bremen und Lübeck (red-white). The design obviously was inspired by the British White Ensign and makes reference to various medieval symbols, such as the cross of the Teutonic Order, and the more recent Iron Cross from the Napoleonic War. After the proclamation of the 2nd Empire on 18 January 1871, this ensign became also the ensign of the Imperial German Navy and remained it until the end of the Empire in 1919. There have been, however, some smaller modifications over the years, thus the eagle was somewhat modified and in 1902 the arms of the cross were made heavier in order to avoid confusion at distance with the White Ensign of the Royal Navy.
Overall, it is rather complex design to reproduce purely manually. First, I had to find a correct image for the ensign, as it looked in about 1878 and was lucky, as the Internet furnished a digital image of sufficient size and resolution. The idea was to print it on both sides of very thin paper (the kind that was used in the old days for carbon copies on type-writer, of which I kept a small supply). Such paper, however, does not feed well through the laser-printer and aligning for double-sided printing is practically impossible. Therefore, I resorted to so-called transfer-sheets. These are a kind of waxed paper that is used to transfer laser-printouts to T-shirts, mugs and such things. Laser-printer toner is basically carbon-black mixed with some plastics powder. It can be remelted with a heat-source, such as an ironing-iron and thus transferred to another substrate. I also experimented with overhead-sheets, but the results were not as good. 

Printing layout for the ensign (as it would appear on the transfer sheet)
 
In a first step, the red stripe in the flag was eliminated from the image in Photoshop, as it would print grey otherwise. The ensign was then scaled to the right size on the basis of some trial-and-error, as the laser-printer prints a few percent undersize. I then added reference marks some distance from the image and duplicated this for mirroring. Several of these left-right-pairs were arranged on an A4-sheet and then printed onto the transfer-sheet using the highest quality print setting.

Preparing the pouch for double-sided toner-transfer to the ensign-blank
 
Using the best matching pair, I made a small pouch (as you would do for the masks, when producing photo-etched parts), aligning the images against each other for a perfect match on an illuminated board (they can be bought for a few €/£/US$ on ebay et al. and are powered through a USB-charger). An oversized strip of the thin paper was slipped in between and everything taped down onto a piece of thick cardboard.
I pressed down an ironing-iron set to the lowest temperature onto the package, which made the toner firmly stick to the paper and no residues left on the transfer-paper. And voilà, a double-sided printed flag with a very detailed eagle etc.

The toner is (almost) completely transferred to the ensign-blank
 
In the next step the missing red stripe was added using red acrylic paint. I also added colour to the legs and beak of the Imperial Eagle, to the Imperial Insignia and the crown using yellow-ochre acrylic paint. If one has a colour laser-printer this step would not be necessary.
The flag was cut out exactly to size, except for the rear, where it was left a tad longer to provide for a hollow ‘seam’ into which a thread with two loops at the end was laid The seam was glued down with some diluted white glue. This area also needed a bit of touch-up afterwards with black acrylic paint.
 
The ensign before adding the colours
 
Draping the flag is best done or least pre-arranged on the flag-staff. The paper was slightly wetted and the flag laid into diagonal folds in alternate directions. Toothpicks ensured that they became folds and not creases, which would be unnatural. Such a large ensign (2.9 m x 4.96 m) would fully unfold only in a moderate breeze and not in the light wind assumed in the scenic setting. So it flaps lazily in the wind, which I tried to reproduce.

The completed ensign
 
To the thus prepared ensign the halliard was attached as a loop. This loop was taken over the top of the flag-staff and a tiny laser-cut paper disc glued on as truck. There was no way to cross-drill the staff for the halliard. The halliard was belayed on the clamp. With this the assembly is ready for installation on the boat. But I will not hoist the ensign before the crew is on board. The recruitment process is still on-going …

Ensign wetted and shaped
 
Sorry, this was a rather lengthy essay on just and ensign, but the idea was to describe in detail, how to arrive on a reasonably realistic looking flag at such as small scale.
 
The ensign attached to the flagstaff
 
To be continued ....

Thanks once more gentlemen for your encouraging praise!
************************************************************
 
Toolkit for the gun
 
The operation of the gun required quite a few different tools for handling the projectiles and the powder-bags, as well as for cleaning and maintenance.
 
There were two different wipers, one for cleaning with soap-water and the other one for greasing the bore after use. This still was the era of black powder, which means that the bore had to be cleaned frequently.
Loading required a rammer to push the projectile and the powder-bags into the chamber of the gun. The rammer also served to unload the gun by pushing it through the muzzle. It had a depression in the front so that one would not push onto the fuse.
 
The large-scale instruction model in the (former) Orlogmuseet in Copenhagen came with many of the necessary tools. Their look tallies with the description of a textbook on the Imperial German naval artillery (Galster, 1885). The length of the shaft was given as the length of the barrel plus some extra for one or two men to be able to hold onto it, while it was fully inserted. If there were not enough space for such long implements, there were also versions in two parts with a brass connecting sleeve.

Wiper (top) and rammer (bottom)
 
The body of the implements was turned from some 2 mm steel rod, as I had this to hand. The shaft is a 0.8 mm piano wire. The latter appears to be quite hefty, but seems to tally with the photographs.

Wipers and rammer before painting
 
As the gun will be shown undergoing a drill, the wipers are not needed and will be shown in their protective canvas covers, stored in the racks on deckhouse as per photograph below.

Wipers in their protective canvas covers
 
The canvas covers were simulated with some Vallejo liquid putty. According to Galster (1885) the covers were supposed to be painted black, but the above photograph indicates that they were white, which is what I opted for.
The rammer body has two copper-bands to protect it, which were simulated with paint. The limited space in barbette seems to prevent the use of a full-length rammer, so I gave the end of the shaft a connecting sleeve simulated with paint.
 
Tampion
The photograph of the instruction model in Copenhagen also shows the expanding tampion that was constructed from two brass discs with some fibre material in between that was contained by a leather sleeve. An internal screw operated by a T-shaped handle squeezed the fibres between the disc and made them expand to lock into the muzzle.

Expanding tampion for the 30,5 cm gun
 
The tampion is probably going to be the very last machined part on this model. It was turned from a length of brass rod. The handle was first turned as a thin disk and then the excess material was milled away to leave the T-shaped handle standing. The greased leather sleeve has been simulated by some brown paint.

Turning the tampion
 

Milling the tampion handle
 
 
The painted wipers, rammer and tampion
 
Next on the list are the anchor-crane, the flagpole and flag and finally the gun-sights
 
To be continued ....

I’ve made a start on hand painting the figures. Being civilians I wanted to mix up some colours. One I get my base coat down I’ll give it a clear coat before weathering 

I think that’s my civilians done for now. I’ll obviously have to change some dirt tones later when I place them in a base 

I have seen historic and contemporary films on YouTube that show the use of English Wheels and there may be one or two that show the construction of shop-made ones.
 
To be honest I don't really see a need for such a gadget in ship-model building. In the automotive sector they are used to reproduce complex and tightly curved panels with beads or similar features. If you use single copper-plates or even whole strakes in most cases no particular shaping apart from pushing it snug against the wooden hull would be needed. In the worst case you could gently rub on it with a round wooden dowel or something like this on a soft and thick cardboard.
 
In boat-building the vertical iron panels for so-called Francis-patent boats were hammered to shape over wooden formers. The same later in the early years of the car industry, before mass-production.

Once again, Thank You for your kind comments !
 

Again, real life including (business) travels got in the way of progress on this project. In addition, while I was having dinner in a restaurant together with colleagues, suddenly some ‘floaters’ appeared in one eye. I went immediately to the eye-doctor, who checked my eyes thoroughly. Luckily the floaters are harmless, but annoying signs of age. No retina-detachment or something else serious. Apparently, they can spontaneously disappear or the brain sort of ignores them after a while – keep fingers crossed. For the moment they are quite bothering, when working on really small things … so on to the ensign.
 
************************************
 
The Imperial German Navy Ensign

This ensign was first conceived for the navy of the North-German Alliance (Norddeutscher Bund) in 1867, bringing together the colours of the dominant powers, namely Prussia (black-white) and the Hanseatic City States, Hamburg, Bremen und Lübeck (red-white). The design obviously was inspired by the British White Ensign and makes reference to various medieval symbols, such as the cross of the Teutonic Order, and the more recent Iron Cross from the Napoleonic War. After the proclamation of the 2nd Empire on 18 January 1871, this ensign became also the ensign of the Imperial German Navy and remained it until the end of the Empire in 1919. There have been, however, some smaller modifications over the years, thus the eagle was somewhat modified and in 1902 the arms of the cross were made heavier in order to avoid confusion at distance with the White Ensign of the Royal Navy.
Overall, it is rather complex design to reproduce purely manually. First, I had to find a correct image for the ensign, as it looked in about 1878 and was lucky, as the Internet furnished a digital image of sufficient size and resolution. The idea was to print it on both sides of very thin paper (the kind that was used in the old days for carbon copies on type-writer, of which I kept a small supply). Such paper, however, does not feed well through the laser-printer and aligning for double-sided printing is practically impossible. Therefore, I resorted to so-called transfer-sheets. These are a kind of waxed paper that is used to transfer laser-printouts to T-shirts, mugs and such things. Laser-printer toner is basically carbon-black mixed with some plastics powder. It can be remelted with a heat-source, such as an ironing-iron and thus transferred to another substrate. I also experimented with overhead-sheets, but the results were not as good. 

Printing layout for the ensign (as it would appear on the transfer sheet)
 
In a first step, the red stripe in the flag was eliminated from the image in Photoshop, as it would print grey otherwise. The ensign was then scaled to the right size on the basis of some trial-and-error, as the laser-printer prints a few percent undersize. I then added reference marks some distance from the image and duplicated this for mirroring. Several of these left-right-pairs were arranged on an A4-sheet and then printed onto the transfer-sheet using the highest quality print setting.

Preparing the pouch for double-sided toner-transfer to the ensign-blank
 
Using the best matching pair, I made a small pouch (as you would do for the masks, when producing photo-etched parts), aligning the images against each other for a perfect match on an illuminated board (they can be bought for a few €/£/US$ on ebay et al. and are powered through a USB-charger). An oversized strip of the thin paper was slipped in between and everything taped down onto a piece of thick cardboard.
I pressed down an ironing-iron set to the lowest temperature onto the package, which made the toner firmly stick to the paper and no residues left on the transfer-paper. And voilà, a double-sided printed flag with a very detailed eagle etc.

The toner is (almost) completely transferred to the ensign-blank
 
In the next step the missing red stripe was added using red acrylic paint. I also added colour to the legs and beak of the Imperial Eagle, to the Imperial Insignia and the crown using yellow-ochre acrylic paint. If one has a colour laser-printer this step would not be necessary.
The flag was cut out exactly to size, except for the rear, where it was left a tad longer to provide for a hollow ‘seam’ into which a thread with two loops at the end was laid The seam was glued down with some diluted white glue. This area also needed a bit of touch-up afterwards with black acrylic paint.
 
The ensign before adding the colours
 
Draping the flag is best done or least pre-arranged on the flag-staff. The paper was slightly wetted and the flag laid into diagonal folds in alternate directions. Toothpicks ensured that they became folds and not creases, which would be unnatural. Such a large ensign (2.9 m x 4.96 m) would fully unfold only in a moderate breeze and not in the light wind assumed in the scenic setting. So it flaps lazily in the wind, which I tried to reproduce.

The completed ensign
 
To the thus prepared ensign the halliard was attached as a loop. This loop was taken over the top of the flag-staff and a tiny laser-cut paper disc glued on as truck. There was no way to cross-drill the staff for the halliard. The halliard was belayed on the clamp. With this the assembly is ready for installation on the boat. But I will not hoist the ensign before the crew is on board. The recruitment process is still on-going …

Ensign wetted and shaped
 
Sorry, this was a rather lengthy essay on just and ensign, but the idea was to describe in detail, how to arrive on a reasonably realistic looking flag at such as small scale.
 
The ensign attached to the flagstaff
 
To be continued ....

Thanks, Kurt, these are interesting insights into the operation of such tow-boats. Of course, if these flanking rudders can move, they make perfect sense, when going backward.
 
This would be a classical application for Schottel-props, but I gather they may be too delicate for the shallow rivers full of debris. There is also a limit to the amount of HP they can bring into the water. Turnable pods with Kort-nozzles would obviate the need for all those rudders, but again debris might be a problem and the shallow draught needed.
 
In the early 20th century for working on shallow (central and eastern) European rivers systems, where the props worked in half-tunnels were developed. Some tow-boats also used early forms of water-jet propulsion to aid maneuvering and turning in tight bends.
 
 

I have a separate hard-drive for backing up everything (as I also use the computer for work) around once a month and I only remove images from the telephone, once I have copies on two independent devices ...
 
I was wondering about these rudders in front of the Kort-nozzles: do they move? If not, the boat would be quite sluggish to turn, I could imagine.
 
And: oh, yes, the project is coming on nicely !

BTW, talking about toolmaker's buttons: I learned about them about 25 years ago, when I purchased from Lindsay Publications (now sadly defunct) a bunch of reprints of early 20th century machinist textbooks and the likes. Among these was
 
JONES, F.D. (1915): Modern Toolmaking Methods.- 309 p., (Industrial Press, reprint 1998 by Lindsay Publications Inc., Bradley IL).
 
Just checked on archive.org and one can now download a copy from there: https://archive.org/details/moderntoolmakingmethodsbyfranklind.jones.

My personal choice would be probably to varnish, though this is not very naturalistic. Just for aesthetics sake.

The contrast between brass and mahagony is always apealing, but I gather, beying 'under water' it will all be painted? Would be a pity for such lovely craftmanship to disappear under paint.

Once again, Thank You for your kind comments !
 

Again, real life including (business) travels got in the way of progress on this project. In addition, while I was having dinner in a restaurant together with colleagues, suddenly some ‘floaters’ appeared in one eye. I went immediately to the eye-doctor, who checked my eyes thoroughly. Luckily the floaters are harmless, but annoying signs of age. No retina-detachment or something else serious. Apparently, they can spontaneously disappear or the brain sort of ignores them after a while – keep fingers crossed. For the moment they are quite bothering, when working on really small things … so on to the ensign.
 
************************************
 
The Imperial German Navy Ensign

This ensign was first conceived for the navy of the North-German Alliance (Norddeutscher Bund) in 1867, bringing together the colours of the dominant powers, namely Prussia (black-white) and the Hanseatic City States, Hamburg, Bremen und Lübeck (red-white). The design obviously was inspired by the British White Ensign and makes reference to various medieval symbols, such as the cross of the Teutonic Order, and the more recent Iron Cross from the Napoleonic War. After the proclamation of the 2nd Empire on 18 January 1871, this ensign became also the ensign of the Imperial German Navy and remained it until the end of the Empire in 1919. There have been, however, some smaller modifications over the years, thus the eagle was somewhat modified and in 1902 the arms of the cross were made heavier in order to avoid confusion at distance with the White Ensign of the Royal Navy.
Overall, it is rather complex design to reproduce purely manually. First, I had to find a correct image for the ensign, as it looked in about 1878 and was lucky, as the Internet furnished a digital image of sufficient size and resolution. The idea was to print it on both sides of very thin paper (the kind that was used in the old days for carbon copies on type-writer, of which I kept a small supply). Such paper, however, does not feed well through the laser-printer and aligning for double-sided printing is practically impossible. Therefore, I resorted to so-called transfer-sheets. These are a kind of waxed paper that is used to transfer laser-printouts to T-shirts, mugs and such things. Laser-printer toner is basically carbon-black mixed with some plastics powder. It can be remelted with a heat-source, such as an ironing-iron and thus transferred to another substrate. I also experimented with overhead-sheets, but the results were not as good. 

Printing layout for the ensign (as it would appear on the transfer sheet)
 
In a first step, the red stripe in the flag was eliminated from the image in Photoshop, as it would print grey otherwise. The ensign was then scaled to the right size on the basis of some trial-and-error, as the laser-printer prints a few percent undersize. I then added reference marks some distance from the image and duplicated this for mirroring. Several of these left-right-pairs were arranged on an A4-sheet and then printed onto the transfer-sheet using the highest quality print setting.

Preparing the pouch for double-sided toner-transfer to the ensign-blank
 
Using the best matching pair, I made a small pouch (as you would do for the masks, when producing photo-etched parts), aligning the images against each other for a perfect match on an illuminated board (they can be bought for a few €/£/US$ on ebay et al. and are powered through a USB-charger). An oversized strip of the thin paper was slipped in between and everything taped down onto a piece of thick cardboard.
I pressed down an ironing-iron set to the lowest temperature onto the package, which made the toner firmly stick to the paper and no residues left on the transfer-paper. And voilà, a double-sided printed flag with a very detailed eagle etc.

The toner is (almost) completely transferred to the ensign-blank
 
In the next step the missing red stripe was added using red acrylic paint. I also added colour to the legs and beak of the Imperial Eagle, to the Imperial Insignia and the crown using yellow-ochre acrylic paint. If one has a colour laser-printer this step would not be necessary.
The flag was cut out exactly to size, except for the rear, where it was left a tad longer to provide for a hollow ‘seam’ into which a thread with two loops at the end was laid The seam was glued down with some diluted white glue. This area also needed a bit of touch-up afterwards with black acrylic paint.
 
The ensign before adding the colours
 
Draping the flag is best done or least pre-arranged on the flag-staff. The paper was slightly wetted and the flag laid into diagonal folds in alternate directions. Toothpicks ensured that they became folds and not creases, which would be unnatural. Such a large ensign (2.9 m x 4.96 m) would fully unfold only in a moderate breeze and not in the light wind assumed in the scenic setting. So it flaps lazily in the wind, which I tried to reproduce.

The completed ensign
 
To the thus prepared ensign the halliard was attached as a loop. This loop was taken over the top of the flag-staff and a tiny laser-cut paper disc glued on as truck. There was no way to cross-drill the staff for the halliard. The halliard was belayed on the clamp. With this the assembly is ready for installation on the boat. But I will not hoist the ensign before the crew is on board. The recruitment process is still on-going …

Ensign wetted and shaped
 
Sorry, this was a rather lengthy essay on just and ensign, but the idea was to describe in detail, how to arrive on a reasonably realistic looking flag at such as small scale.
 
The ensign attached to the flagstaff
 
To be continued ....