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What are CUTTING FILES & Assembly PLANS ?

You will notice that we offer "Cutting files and Plans" for some some of our boat kits.  What does this mean ?  These Cutting Files are the same AutoCad files that we send to to our cutting shop for the kits to be cut for delivery world-wide. If you prefer to have the kit cut by a local cutting shop, then we can supply the files on a CD that will enable you to have the kit cut locally.
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Above are 40 sheets of 18' x 4' of steel plate laid out showing the cutting & reference lines.
This is what the cutting files look like in AutoCad. Your local cutting shop will use these files to cut out and mark you kit. There are between 450 and 1,000 parts in each kit.

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This is the same set of parts cut and laid out as they will be assembled into your hull deck and superstructure. There is a lot more information all about the cutting files and kits in the book  METAL BOATS.

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This is the type of machine your local cutting shop will use to cut out your kit.


The DRAWINGS associated with a the CUTTING FILES are AutoCAD drawings … Release 2000 i   If you do not have this version of AutoCAD then you will need to have the drawings printed out by our selves or your local service print centre.

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 centre.

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 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 CUTTING FILES

The STUDY PLANS show many 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 aluminium 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 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 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 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 80 and 200 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 PLANS:  The assembly 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.


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This Catalogue contains KIT designs and special offers not shown on our web site
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All types of Sail and powerboats that you can build from our Steel or Aluminium pre-cut hull, deck and superstructure construction kits.
Catalogue contains more information about how to acquire your next boat for less. This catalogue contains the  PRICES for all the kits and puts you in the loop to receive special discounts that are often available on selected kits.
When we have an order for a particular model, we are able to offer YOU a special discount on a similar kit.

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