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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 11 contains stages 35-38
Stage 35 – Contains Gearbox (L) Gearbox (R) Inner CV Joints x2 and screws
The inner CV joints and gearbox L and R
Take a closer look at the gearbox (L) and one of the inner CV joints – the joint has three arrowed projections that will fit into the circular holes in the gearbox.
Make sure these pins and holes are aligned, then press the CV joint into place.
Holding the parts in place, turn the assembly over and tighten a screw G into the circled hole with the screwdriver.
Repeat this process for the gearbox (R) and the other inner CV joint.
The engine oil line
Retrieve the engine oil line from Stage 34.
The engine oil line will be attached to the gearbox (L) via the holes pictured below.
Apply a small amount of adhesive to the tip of the oil line and Insert the straight tip of the engine oil line into the lower circular hole.
Next, apply a small amount of adhesive to the curved tip of the oil line then fit the curved tip into the hole as shown below.
Stage complete :The left and right sides of the gearbox have their CV joint fitted, and the engine oil line is in place.
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 36 – Contains Gearbox inner (L) Gearbox inner (R) Rear shock reservoir uppers x 2 Rear shock reservoir lower (L) Rear shock reservoir lower (R) and screws.
Tools Required:
ABS adhesive
Phillips screwdriver (size 00)
Phillips screwdriver (size 0)
Cutter
Assembling the gearbox Part 2
Perform a test fit of the parts before applying any adhesive. Join the parts then check that the four screw holes are unobstructed.
Separate the parts and apply some adhesive to the inner area then re-join the parts and hold them together for a few minutes.
Insert a screw G into each of the four holes identified during the test fit, and tighten with the size 0 screwdriver. Make sure there are no gaps between the parts.
The gearbox inners are now complete.
Carefully remove the gearbox oil line union C (BLUE) from the sprue provided with this stage. (Pictured below)
Carefully Remove any of the sprue left over when removing.
Fetch the left and right gearbox parts assembled in Stage 35.
Line up the right gearbox assembly from Stage 35 with the right gearbox inners joined at the beginning of this stage. The mounting post will fit into the hole.
Next, test-fit the assembly by adding the gearbox (L) from Stage 35.
With the parts in place, Seal the part by adding the right gearbox from Stage 35. Before proceeding, check that the circled holes are unobstructed from both sides.
Remove the right gearbox and apply some adhesive to the outer areas, then replace the part and hold the assembly together for a few minutes to bond the parts.
Tighten a screw J into each of the holes highlighted during the test fit, using a size 00 screwdriver.
Carefully turn another screw J through the hole in the gearbox oil line union C, from the front side.
Insert the tip of the screw into the hole in the gearbox (L) and tighten it to secure the gearbox oil line.
Place the part in the position shown below before fully tightening the screw.
Insert and tighten two more screws J into the holes, again using a size 00 screwdriver as shown below.
Assembling the rear shock reservoirs
Test-fit the left rear shock reservoir lower to one of the rear shock reservoir uppers.
Line up the side bar of the reservoir lower with the mark left over from the plastic moulding process as shown below.
Scrape away some of the silver paint from the inside of the circled area.
Separate the parts, then apply a little plastic adhesive to the edge of the reservoir upper. Re-join the parts and hold them together for a few minutes.
Repeat this process for the right reservoir lower and the second upper.
Stage complete :The gearbox is beginning to take shape, and both rear shock reservoirs are prepared for the coming stages. Keep the unused plastic parts from Stage 34 in a safe place until next time.
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 37 – Contains Brake duct (R) Rear upright inside (R) Rear upright middle (R) Outer CV joint, Axle spacer Rear upright outside (R) Axle, Axle shaft and screws.
Tools required:
Plastic adhesive
Phillips screwdriver (size 00)
Phillips screwdriver (size 0)
Cutter
Assembling the right rear upright
Test-fit the axle into the rear upright outside, with the projections on the axle fitting into the notches on the upright as shown below.
Carefully scrape away the paint from the indicated areas of the axle as shown below.
Dab the areas of the rear upright outside with adhesive, then fit the parts together as you did for the test fit. Press the parts together for 2-3 minutes while the adhesive dries.
Fitting the axle spacer, CV joint and axle shaft.
The axle spacer fits over the indicated circular section of the axle. It doesn’t matter which way around you fit it. Now place the CV joint into the centre of the assembly.
Turn the assembly over, and push the flattened end of the axle shaft into the hole in the centre of the axle.
Turn the assembly around and tighten a screw E into the circled hole with the size 0 screwdriver.
Adding the rear upright middle and inside.
Test-fit the rear upright middle and outside, so that you know how they should be placed when the adhesive is applied. The notch should line up with the outcut.
Next, test-fit this dry assembly to the rear upright inside, making sure the 3 screw holes line up neatly.
Scrape away some of the paint from the outer area of the upright and axle assembly.
Also remove some of the paint from the inside edge of the rear upright middle.
Gluing the rear upright parts together.
Apply some HIPs adhesive to the area of the upright outside assembly, then slide on the upright middle and hold the parts together for 2-3 minutes.
Do not apply the adhesive any closer to the body of the upright outside, as it may spill over when you add the middle part.
Now apply some adhesive to the flat surface of the upright middle and fit the upright inside.
Tighten three screws R into the indicated holes with the size 00 screwdriver.
Stage complete: This completes the assembly of the second rear upright, which has been equipped with its axle and CV joint.
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 38 Contains the Rear lower wishbone, Rear lower wishbone brackets x 2, Rear pushrod bracket outside (L), Rear pushrod bracket outside (R) and screws.
Tools Required:
Phillips screwdriver (size 0)
Phillips screwdriver (size 00)
Tweezers
Masking tape
Assembling the rear lower wishbone.
Fitting the pushrod brackets to the rear lower wishbone
Lay your rear lower wishbone out on your work surface and locate the two rectangular recesses as shown below.
Place the right bracket into the right recess aligning the hole as shown below.
Hold the bracket in place with your finger, and turn the assembly over.
Place a screw R onto the tip of the size 00 screwdriver.
Insert the screw into the circled hole and tighten.
Keep turning until the screw until its end appears on the other side of the bracket.
Repeat to attach the left pushrod bracket to the other side of the wishbone.
Attaching the wishbones to the gearbox.
Fetch the gearbox assembled in Stage 36.
Pick up one of the rear lower wishbone brackets with the tweezers – holding it by the opposite side to the one that has the threaded hole.
Line up the bracket with the square space on the left side of the gearbox as shown below.
Place the bracket this into this space, then tighten a screw G into its central hole to fasten the part in place. Repeat for the other side.
Stage complete: The rear lower wishbone brackets are attached to either side of the gearbox, and the wishbone has been fitted with the pushrod brackets.
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 12 contains stages 39-42
Stage 39 Contains: Bellcrank top (L)&(R) Bellcrank lower (L)&(R) Rear pushrods x 2 and screws
Assembling the left bellcrank and pushrod
Place the eye of a rear pushrod over the indicated pin on the left bellcrank top, making sure you follow the orientation shown in the photo.
Fit the pins on either side of the left rear shock absorber’s cap into the indicated grooves on the left bellcrank lower.
Now join the left bellcrank top and pushrod assembly to the bellcrank lower.
Make sure that the shock absorber can pivot freely.
Insert a screw R into the circled hole and tighten with a size 00 Phillips screwdriver.
Assembling the right bellcrank and pushrod
Repeat the procedure described in the previous step.
Stage complete: The left and right rear shock absorbers and pushrods have been fitted to their bellcranks.
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 40 Contains: Rear suspension mounting plate (front). Rear suspension mounting plate (Back). Rear anti-roll bar. Gearbox upper Hose B (1.4 x 700mm). Screws J (1.4 x 6P-M BK) x 9
Fitting the gearbox oil line adapter to the gearbox
Fetch the gearbox oil line adapter (Stage 34).
apply a little plastic adhesive to the gearbox upper’s recess and press the oil line adapter into it for a minute.
Fitting the bolts (1) and (2)
Fetch the sprue of plastic parts saved from Stage 34
Turn the sprue upside-down and place it on a cutting mat, then very carefully remove a single bolt with your cutter. As the parts are small, remove only one at a time to avoid losing them.
Use tweezers to place a bolt into each of the three holes in the gearbox upper marked by the red arrows.
With the sprue still upside-down on your cutting mat, carefully cut off the bolts with the cutter, using the red lines as a guide.
Insert the bolts into the two holes in the gearbox upper marked by the red arrows, inserting them cut end first. Turn the gearbox upper over and dab a little adhesive onto the indicated holes to secure the bolts.
Preparing hose B
Use a ruler to measure a point 19mm from the tip of the hose B, and dab this point with some adhesive.
Once the adhesive has dried (about one minute) cut the hose at this point.
Widen the cut end of the 19mm hose a little, using the tip of a toothpick.
Repeat this process to prepare one more 19mm length of hose and one length of 135mm.
Connecting the brake line T-piece
Fetch the brake line T-piece from stage 34.
Dab a little adhesive to the indicated pin on the T-piece
Push the widened tip of the 135mm-long hose B length over the pin. Hold this in place for a minute.
This step is now complete.
Fitting the shock reservoirs
Lay out the rear shock absorbers and pushrod assemblies (Stage 39) on your work surface, along with the rear shock absorber reservoirs (Stage 36).
Lay out the parts as shown in the photo below.
Place the shock absorbers so that the sides on which the pins do not have a step between them and the plastic body are uppermost, as are the rectangular projections on the two shock caps.
Dab the pin on the left shock reservoir with a little adhesive.
Now push the widened tip of one of the 19mm-long sections of hose B onto this, and hold it in place for one minute.
Dab the pin on the end of the left shock absorber with some adhesive.
Push the free end of the 19mm length of hose B fitted to the shock reservoir over the pin, and hold it in place for one minute.
Make sure that the rectangular projections on the shock reservoir and shock absorber cap are both facing forwards before you hold the hose B in place while the glue dries.
Repeat this process so that the second 19mm length of hose B is glued to the right shock absorber and pushrod assembly, as shown.
Stage complete: At the end of this stage, the gearbox upper has its bolts glued in, the brake line T-piece has its hose attached, and both shock absorbers are connected to their shock reservoirs.
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 41 Contains: Quarter panel (L) Rear upper wishbone (L) Toelink (L) Toelink bracket and assorted screws
Adding the gearbox oil line union and hose B
Lay the gearbox assembly (Stage 38), length of hose B (Stage 40) and plastic parts sprue (Stage 34) out on your work surface.
Carefully separate the oil line union (shown below) from the sprue then Using a toothpick, drop a small amount of adhesive into the hole in the right-hand side of the gearbox assembly as shown below.
Use tweezers to place the gearbox oil line union into the hole.
Measure a point 68mm from the tip of the length of hose B, and dab this with glue. Once the glue has dried, cut this point using a sharp knife. Now glue this to the union that you have just fitted.
Attaching the suspension mounting plate to the gearbox
Slide the rear suspension mount (rear) onto the gearbox so it sits in the indicated grooves as shown below.
Insert one of the screws J into the circled hole on the right side of the gearbox assembly and tighten it with a screwdriver.
Turn the assembly around and repeat to secure the other side of the mounting plate.
Adding the suspension
Line up the hole on the left shock absorber to the one the left of the gearbox and insert a screw J into both, using a screwdriver. Only half-tighten the screw at this point.
At the bellcrank end of the left suspension assembly, place the indicated post into the circled hole on the suspension mounting plate.
Repeat this process to attach the right suspension assembly to the other side of the gearbox and mounting plate and tighten the 2 J screws.
Identify the front and back of the rear suspension mounting plate (front) by locating the rectangular cutaways indicated in the photo.
Slide the mounting plate, back side first, onto the gearbox assembly so that it sits on the ledge with the holes accommodating the posts on the bellcranks.
Insert and tighten another screw J into the circled hole in the left side of the assembly.
Turn the assembly around and tighten another screw J into the corresponding hole on the right side.
Slot the rectangular projection of the left shock reservoir upper into the indicated hole in the gearbox.
Repeat for the right-hand side of the assembly.
Stage complete: The gearbox has been fitted with its oil line hoses and with the suspension systems that will eventually carry the rear wheels.
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 42 Contains: Quarter panel (R) Rear upper wishbone (R) Toelink (R) Toelink bracket and assorted screws
Assembling the gearbox 5
Fit the rear lower wishbone into place on the gearbox, so that the two eyes fit inside the brackets, and the wishbone’s flat, straight section slots into the groove.
Tighten a screw P into the underside of the bracket holding the pushrod.
Repeat for the opposite side of the assembly.
Bring the wishbone up so that the bracket fitted to it accommodates the free end of the pushrod, as shown. Then join them together by fastening a screw M through the holes in them.
Repeat this process to join the pushrod and wishbone on the other side of the assembly.
Fitting the brake line T-piece to the gearbox upper
Fetch the brake line T-piece assembly and gearbox upper.
Push the pin on the underside of the brake line T-piece into the hole in the gearbox upper.
Holding the parts in place, turn the assembly over and dab the circled hole with some adhesive.
This step is now complete.
Mounting the toelink bracket
Lay the toelink bracket (Stage 41), two screws J (Stage 40) and screw G (Stage 41) out on your work surface.
Place the gearbox upper onto the gearbox assembly.
The parts should fit together neatly.
Tighten a screw J into both circled holes to secure the parts.
Now locate the circled hole on the left-hand side of the gearbox assembly, and loosely fasten the toelink bracket to this using the screw G.
Rotate the bracket so that the side that has the slightly raised, threaded hole in it is facing forward.
When the position of the bracket is correct, tighten the screw fully with a screwdriver.
Repeat the above procedure for the right hand side toelink.
Installing the anti-roll bar and drop links
With the sprue lying upside down on a cutting mat, very carefully separate each drop link by cutting through at the points.
Using tweezers, place the ring of the drop link over the indicated pin on the right bellcrank, so that the drop link’s pin faces upwards.
Repeat for the drop link on the left-hand side of the assembly.
Use a toothpick to dab a small amount of adhesive onto the tip of each drop link and the sections of the mounting plates.
Lower the anti-roll bar onto the gearbox upper and glue into position as shown below.
Stage complete: The gearbox has both pushrods and both lower wishbones attached, and the brake line T-piece and anti-roll bar are fitted at the top of the assembly.
Warthog attached the following image(s):
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