STEP BY STEP
HOW TO ASSEMBLE PLASTIC BUILDINGS
1
As well as pre-formed components, such as window frames, doors and detail fittings, Wills’ Craftsman Kits mostly consist of sheets of embossed plastic that must be cut and shaped following the full-size plans supplied.
2
The plans provide all of the necessary dimensions and these can be transferred to the back of the embossed sheets with a fine marker pen. Remember to note the identity of each section, to help during assembly.
3
When cutting, use a fresh blade and make several light passes, allowing the knife to work through in its own time. All outer faces must be straight and true. Tidy the edges with a broad, flat file and check with a set square.
4 Having marked out the window and door apertures, drill holes near each corner, well within the waste material. Thread the blade of a piercing saw through one hole and cut away most of the waste.
5 Repeat the work with the drill and piercing saw and then use a file to refine each aperture to the exact dimensions, checking the fit of the window and door frames. Use sanding sticks to remove any file marks and tidy the edges.
6 To achieve neat corner joints and continuity in the stone courses, the mating faces need to be chamfered to 45º. With the wall held over the edge of a scrap of wood, gently form the chamfer with a file, aiming for an even profile.
7 A set of magnetic corner clamps makes alignment so much easier. Set one side and end wall together and apply liquid poly cement to the inside of the joint. Fit the internal corner fillets to strengthen the joints.
8 Repeat with the other side and end wall. When each has dried, bring the two halves together and clamp the corners while making the glue bonds and add the fillets. Double-check angles before setting aside to dry overnight.
9 Depending on the size of the structure, internal reinforcing walls may be worth installing. I used an offcut of the embossed stone sheet, cut it to the required size and aligned it squarely. Again, the corner fillets were added for strength.
10 The roof sections can be cut to size and the upper mating faces must also be chamfered, so that they meet neatly at the apex. Ensure that there’s an equal overhang of each wall when fixing in place.
11 Allow the roof to cure before filing the apex flat in order to accept the ridge tile moulding. The chimney is formed from four walls, in the same manner as the main structure. When fixed, fill gaps around the base with putty.
12 Any gaps in the wall corners can also be addressed with putty. When dry, a mini steel brush will clear the mortar courses of debris. Applying more liquid poly cement into the courses will also help tidy up the stonework.
13 With the main shell complete, smaller detail fittings can be added, such as gutters, window ledges and doors. The Wills Craftsman kits provide all of the necessary materials, which simply need cutting to size.
14 After painting, the window frames can be secured to the inside. Clear acetate sheet was employed for the glazing, cut to size with scissors and secured to the inside of the frames with Glue ‘n’ Glaze, a Pva-based glue.