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 Rank: Elite        Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Pack 5 contains stages 15 - 17
Stage 15 – Contains Radiator Mesh left, Radiator left, Left intercooler top and left intercooler bottom.
Tools required: Instant Adhesive (SuperGlue) A sharp Knife and a cutting Mat.
TIP: Test fit all parts before applying any Adhesive.
Assembling the left intercooler
Take the left intercooler assembly from Stage 10 and the left intercooler balance pipe from Stage 14.
Remove any chrome paint with a diamond file as shown below.
Now locate the projection on the side of the left intercooler . Apply a small amount of superglue (CA) with a toothpick to the left intercooler and the left intercooler bottom and fit together.
Apply a small amount of superglue (CA) to the end of the intercooler pipe and fit the end of the intercooler balance pipe into the intercooler bottom as shown below. Ensure that the notch in the end of the pipe is properly aligned with the projection in the intercooler bottom.
Apply a small amount of Superglue to the intercooler top and Place the intercooler top onto the intercooler assembly and over the two projections at the top of the intercooler as shown below.
Hold the parts together and allow to dry.
Preparing the left radiator parts.
Scrape away the paint from the areas shown below on the front and back sides of the left radiator mesh.
Now scrape away the paint on the insides of the two recesses at the side of the radiator as shown below.
Stage Complete
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 16 – Contains the Monocoque.
Tools required for this stage: HIP’s adhesive, A sharp knife, Cutting mat, Some masking tape and a Mechanical pencil.
Parts required for this stage:
The left radiator housing (Stage 9)
The left radiator housing base (Stage 9)
The left monocoque side panel (Stage 9)
The Battery (Stage 13)
Left floor support (Stage 13)
Left radiator inlet (Stage 14)
Left radiator outlet (Stage 14)
Left radiator (Stage 15)
Left radiator mesh (Stage 15)
TIP: Test fit all parts before gluing.
Gluing the left radiator housing parts:
Take the radiator mesh and apply plastic adhesive to the sides from which the paint was removed.
Fit the radiator mesh into position in the radiator housing as shown below and hold the parts in place for 2-3 minutes to let the glue set.
Pass the LEFT floor support through the radiator mesh and into the radiator housing, and fix the other end to the glued cut-out. Hold in place for 2-3 minutes to allow the glue to set.
Fit the battery into the recess in the radiator housing. Note the position of the battery and hold in place for a couple of minutes until the glue has set.
Apply plastic adhesive to the bottom edges of the radiator housing walls and fit the two radiator housing parts together and check along the joins to make sure there are no gaps.
Place masking tape to the base and to the side of the housing to hold the parts together as the glue dries. Leave for about an hour before removing the tape.
Preparing the left radiator parts:
Take the left radiator inlet and outlet from Stage 14 and the left radiator from Stage 15.
Apply a small amount of HIP’s adhesive to the smallest hole at the side of the radiator shown below. Place the outlet into position, inserting the projection on the back into the hole in the radiator. Hold it there for 2-3 minutes to allow the glue to set.
Now apply HIP’s adhesive to the larger hole in the side of the radiator, above the outlet that you have just glued. Insert the projection on the back of the inlet into the hole, and hold in place for 2-3 minutes as the glue dries.
Preparing the left monocoque side panel and the monocoque:
Place the Monocoque side panel onto the Monocoque as shown below. Holding the monocoque side panel in place, gently mark around the edges onto the side of the monocoque with a pencil.
Scrape away the paint from the monocoque side and the side panel, 5mm in from the edges (marked outlines as shown below).
Apply HIP’s adhesive to the part of the side panel from which you removed the paint. Apply only a little, so that it doesn’t spread past the edges of the panel when fixed to the monocoque.
Place the left monocoque side panel into position on the side of the monocoque, and hold it in place for 2-3 minutes to allow the glue to set.
Stage Complete
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 17 – Contains the Monocoque endplate, Head Panel, Intercooler outer and the intercooler inner.
Tools Required for this stage:
HIP’s adhesive
Instant adhesive
A sharp Knife
Cutting mat
Some Masking tape
TIP: Use the images below to check that you have the parts fitted correctly before gluing into position.
Fitting the Left Radiator to the radiator Housing:
Take the left radiator housing and left radiator that you assembled in stage 16 and test fit the radiator to the housing. Remove any paint from the areas shown.
Apply HIP’s adhesive to the areas that you removed the paint from and fit the radiator to the radiator housing as shown below. Secure the radiator in position with masking tape and allow to dry.
Fitting the intercooler to the radiator housing:
Apply a few dabs of Superglue (CA) to the top and bottom of the projection at the back of the intercooler and place the intercooler back into the hole in the radiator housing shown below and hold it there for 1 minute.
Stage Complete
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Pack 6 contains stages 18 - 20
Stage 18 – Contains the Right Side Radiator Housing, The Right Side Radiator Housing Base and the Right side Monocoque Panel.
Tools Required:
ABS adhesive
A sharp Knife
Cutting mat
Retractable pencil
Parts required for this stage:
Solenoid valve unit (Stage 13)
Right radiator inlet (Stage 14)
Right radiator outlet (Stage 14)
Monocoque (Stage 16)
Right intercooler (Stage 17)
TIP: Test fit all parts before applying Adhesive.
Fixing the solenoid valve unit to the right radiator housing
Retrieve the solenoid valve unit that you assembled in Stage 13 and Apply a little ABS adhesive to the area on the back of the unit as shown in the picture below.
Now place the valve unit onto the radiator housing as shown in the picture below. Hold together for a few minutes as the adhesive dries.
Preparing the right intercooler.
Retrieve the right intercooler that you assembled in stage 17 and remove any paint from the out edge as you did for the left hand side.
Now take the Inlet and outlet pipes from Stage 14 and remove any paint from the areas to be glued as you did for the Left hand side.
Take the Monocoque side panel and test fit it to the side of the Monocoque, then remove the area of paint from the back of the panel as you did for the left hand side.
Apply Adhesive to the area that you removed the paint and fit the side panel to the Right hand side of the Monocoque.
Stage Complete
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 19 – Contains the Right Radiator, the Right Radiator mesh, the right intercooler top and the right intercooler bottom.
Tools required for this stage:
HIP’s adhesive
A sharp Knife
Cutting mat
Masking tape
Parts Required for this stage:
Floor support right (Stage 13)
Right radiator inlet (Stage 18)
Right radiator outlet (Stage 18)
Right radiator housing (Stage 18)
Right radiator housing base (Stage 18)
Tip: Remember to test fit all the parts before applying any adhesive and use the photo’s below for guidance.
Assembling the right intercooler:
Take the radiator mesh and apply adhesive to the sides from which the paint was removed as shown.
Fit the radiator mesh into position in the radiator housing as shown below and hold the parts in place for 2-3 minutes to let the glue set.
Pass the remaining floor support through the radiator mesh and into the radiator housing, and fix the other end to the glued cut-out. Hold in place for 2-3 minutes to allow the glue to set.
Fitting the radiator housing base to the radiator housing:
Apply plastic adhesive to the bottom edges of the radiator housing walls as you did for the left side and fit the two radiator housing parts together and check along the joins to make sure there are no gaps. Take some masking tape and secure the parts together and allow to dry before removing.
Assembling the intercooler:
Take the right radiator inlet and outlet from the previous stage and the left radiator from Stage 18.
Remove the paint from the two indentations where the inlet and outlet pipes will be fitted.
Now apply a small amount of HIP’s adhesive to the smallest hole at the side of the radiator shown below. Place the outlet into position, inserting the projection on the back into the hole in the radiator. Hold it there for 2-3 minutes to allow the glue to set.
Now apply HIP’s adhesive to the larger hole in the side of the radiator, above the outlet that you have just glued. Insert the projection on the back of the inlet into the hole, and hold in place for 2-3 minutes as the glue dries.
Stage Complete
Warthog attached the following image(s):
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Rank: Elite Groups: registriert, Registered Joined: 20/03/2011 Posts: 2,356 Points: 7,122 Location: UK
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Stage 20 – Contains Turbo Charger intakes left and right and Turbo Charger intake adaptors.
Tools required:
HIP’s adhesive
Instant adhesive (SuperGlue)
A sharp Knife
Cutting mat
Masking tape
Tip: Removing gate marks and casting flash:
You may have found that cast parts such as the turbocharger air intake parts have marks left on them from the casting process. These marks will affect the quality of the adhesion when you glue the parts together, but can also be used as markers when combining parts. Carefully remove any Casting flash with a sharp knife or a needle file. (Take extra care when using a sharp knife at all times and never cut towards you)
Parts required for this stage:
Right intercooler balance pipe (Stage 14)
Right intercooler (Stage 18)
Right intercooler top (Stage 19)
Right intercooler bottom (Stage 19)
Gluing the left turbocharger air intake parts together:
Apply HIP’s adhesive along the outside edges of the turbocharger intake inside, and then combine the the two parts together. Hold them for a few minutes until dry.
When the glue is dry, remove any marks from the end of the intake.
Apply HIP’s adhesive to the now smooth end of the intake. Place the adapter back into the end of the intake and hold it there for a few minutes until the glue begins to dry.
(You may want to label the left turbocharger air intake)
Assembling the right turbocharger air intake:
Test-fit the right turbocharger air intake parts together, as with the left turbo in the previous step. Then glue the parts together in the same way as you did with the Left. Leave to dry and label “R” for the right side.
Preparing and assembling the right intercooler parts:
Have the right intercooler balance pipe (Stage 14), right intercooler (Stage 18), right intercooler top (Stage 19) and right intercooler bottom (Stage 19) ready.
Test fit all the parts and assemble them as you did with the Left intercooler in Stage 15
Stage Complete
Warthog attached the following image(s):
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