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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 13 contains stages 43-46
Stage 43 – Contains: Engine oil tank upper, Engine oil tank lower, 2 x Driveshaft’s, The gearbox bottom and Assorted screws.
Mounting the gearbox bottom
You will need the gearbox assembly from Stage 42.
Line up the gearbox bottom with the underside of the assembly, lining up with the groove and Fit them together.
Now insert a screw J into each of the holes and tighten with a size 00 screwdriver.
Building up the gearbox
Retrieve the left quarter panel, left rear upper wishbone and the two screws G saved from Stage 41.
Use a screwdriver to remove the screw M joining the rear lower wishbone and pushrod on the left-hand side of the gearbox assembly
Raise the disconnected pushrod upwards and slot the left quarter panel into the space between it and the wishbone. Use the coloured arrows below to help you get the panel orientated correctly.
Fit the slot at the front of the panel over the front arm of the wishbone then fit the hole over the small pin. The rear arm of the wishbone fits into the notch.
Lower the pushrod again, and re-attach it to the wishbone, using the screw you removed earlier.
Next, slide the arms of the left rear upper wishbone in between the holes on the rear suspension mounting plate (front). When it’s in position, secure it with two screws G. At this point, the parts are only temporarily attached.
The loose quarter panel will be secured properly via a screw through the blue-arrowed hole at a later stage, so until then, take care when handling the assembly.
Installing the brake duct and driveshaft
Retrieve the left rear brake duct supplied with Stage 33.
Insert one of the driveshafts into the hole in the centre of the brake duct.
Using a toothpick, dab little instant adhesive on the flattened tip of the driveshaft.
Holding the driveshaft and brake duct with the flattened side of the driveshaft tip facing towards the back of the gearbox, slot the shaft through the notch in the top of the panel.
Push the tip of the driveshaft into the hole in the centre of the CV joint.
Fitting the left rear brake
Fetch the rear brake assembly built in Stage 33.
Line up the brake assembly to the open face of the brake duct fitted in the previous step.
Carefully fit the parts together.
Slide the brake and brake duct over the upper wishbone so that its tip enters the gap beneath the screw hole. When it’s in place, secure it by tightening a screw C into the hole. Slide a washer A onto a screw K.
Insert the screw through the hole in the forward-facing tip of the lower wishbone, and tighten. Be careful not to overtighten it.
Attaching the toelink
Retrieve the toelink (L) and a screw P, both saved from Stage 41.
Place the silver end of the toelink into the toelink bracket.
Tighten the screw P through the bracket and the loop at the silver end of the toelink.
Do not overtighten the screw – stop turning as soon as the screw head touches the side of the bracket.
Line up the free end of the toelink to the hole on the brake duct. Then use a screw M to fix these parts together.
Again, tighten the screw only lightly.
Stage complete
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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 44 contains: Oil cooler, Jacking hook left, right and Middle. Gearbox rear and assorted screws.
Mounting the oil cooler
Test-fit the oil cooler by slotting the base, outlined here in blue, into the indicated slot
Fit the oil cooler into position and hold it in place until the glue has set.
Preparing wire A and hose B
Cut off a 62mm length of wire A.
Dab the end of hose B with instant adhesive, using the method explained in Stage 40. When it’s dry, cut off a length of 18mm. Repeat to create another length, this time of 84mm.
When cut, widen the ends of the 18mm length a little with a toothpick.
Connecting the oil cooler and oil line unions
Apply a small amount of adhesive to the pin of the oil line union on the left side of the gearbox, then place the tip of the 15mm hose over it and hold the hose in place for one minute.
Now dab the pin on the oil cooler with adhesive and push the free end of the hose over it, again holding the hose place for a minute while the adhesive dries.
Connecting the oil line union
Lay the gearbox assembly out on your work surface with the right side facing you, then insert the 62mm length of wire you made in the previous step into the free end of the hose, the one leading to the oil line union fitted in Stage 41.
When the wire is in place, make a 90° bend in it 6mm from the hose, using tweezers.
Bend the hose so that it leads towards the rear of the gearbox, and up towards the hook-shaped pin.
Bend the hose gently around the corners.
Dab the pin on the oil cooler with instant adhesive, then push the end of hose B over it. Hold the hose in place for one minute.
The oil cooler and oil line union are now attached.
Continuing the gearbox assembly
Retrieve the sprue of plastic parts supplied with Stage 34.
With the sprue facing downwards on a cutting mat, carefully separate the oil line union pictured below.
Be very careful when cutting these small parts from the sprue
Test-fit the oil line union by sliding its black base into the slot on the gearbox rear.
The end of the union’s base next to the silver part should enter the notch first.
When you are happy with the fit of the part, apply a little instant adhesive to the black base and re-insert it. Hold it in place for about one minute.
Dab the free end of the oil line union with adhesive then push the end of the 84mm length of hose B over it, using tweezers. Hold it in place for about a minute, while the adhesive dries.
Line up the gearbox rear to the gearbox assembly so that the hole at its centre lines up with the hole inside the gearbox’s body.
Insert and tighten a screw J into the aligned holes to secure the parts.
Mounting the gearbox oil union
Carefully remove the gearbox oil line union pictured from the sprue, by placing the sprue face down on your cutting mat and using a cutter. Be careful not to damage the part itself.
Dab the indicated end of the part with adhesive and then push the free end of hose B over it.
Dab the other end of the union with adhesive.
Feed the hose underneath the one fitted earlier as shown below. Next, feed the hose underneath the rear suspension mounting plate and up across the gearbox.
Dab the end of the oil line union with adhesive then insert it into the hole in the top of the gearbox. Hold the union in place until the glue has set.
Stage complete
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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 45 contains: Brake calipers outer x2, brake calipers inner x2, Brake disk inner, brake disc outer and 4x brake pads.
Assembling the right rear brake disc and calipers.
Assemble the discs and calipers as you did for the left rear in stage 32
Attaching the jacking hooks
You will need the jacking hooks L, R and Middle which were supplied in Stage 44, together with your gearbox assembly.
Test-fit the right-hand jacking hook (jacking hook R) to the rear of the gearbox, so that the pins fit into the grooves as shown in the picture below.
When you are happy with the fit, remove the hook, apply some instant adhesive and re-attach it. Hold it in place until the adhesive has set.
Next, dab instant adhesive onto the end of jacking hook M.
Fit this end into the hole as pictured below and hold it in place until the adhesive has set.
Dab the exposed end of jacking hook M with instant adhesive, using a toothpick.
Press the jacking hook L into place opposite jacking hook R, fitted previously then fit the tip of jacking hook M into hook L’s outermost hole. Hold them together for a minute.
This completes the assembly of the rear jacking hooks.
Stage complete
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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 46 contains: Rear tyre and rear wheel.
Fitting the tyre
As you did for the first rear tyre in Stage 14, press the tyre onto the wheel with the ‘G’ in the ‘EAGLE’ logo aligned with the circled indent on the wheel.
Assembling the engine oil tank top
Retrieve gearbox oil line union from Stage 34 and both parts of the engine oil tank top (upper and lower) from Stage 43.
Test-fit the two halves of the oil tank by placing the lower part inside the upper.
When you are happy with the fit, apply some adhesive and rejoin the parts. Hold them together for a minute until the adhesive has set. Scrape the paint away from the surface of the oil line union using the cutter. Dab the stripped surface with instant adhesive.
Slot the part neatly into the indicated notch in the side of the oil tank, then hold in place for a minute while the glue dries.
Adding the right quarter panel and upper wishbone to the gearbox
Lay out the right quarter panel, rear upper wishbone and two screws G from Stage 42, along with the gearbox assembly from Stage 45, on your work surface.
Remove the screw M from the end of the right rear lower wishbone as you did when you fitted the left quarter panel in Stage 43, raise the toelink away from the lower wishbone and slot the quarter panel into place along the side of the gearbox orientating the parts correctly.
Fit the panel into place, with the areas aligned correctly. Lower the toelink again so that it rejoins the tip of the wishbone, then re-insert the screw M and tighten it.
Next, slide the arms of the upper wishbone in between the holes on the rear suspension mounting plate. When it’s in position, secure it with two screws G.
Stop tightening the screws as soon as their heads touch the parts.
Fitting the right-hand driveshaft, brake duct and toelink
Retrieve the right rear brake assembly (Stage 45), the right rear brake duct (Stage 37) and the right toelink and screw P (Stage 42), along with the driveshaft, a screw K, a screw M and a washer A (all from Stage 43) for this step.
Insert the driveshaft through the hole in the brake duct from the side shown.
Dab the tip of the driveshaft with instant adhesive.
With the flattened surface of the driveshaft tip facing towards the rear of the gearbox, and the open face of the brake duct facing outwards, slide the shaft through the notch in the quarter panel.
As you did in Stage 43, fit the tip of the driveshaft into the centre of the CV joint. Once in place, hold the parts together for one minute.
Line up the brake assembly with the open face of the brake duct fitted in the previous step.
Carefully fit the parts together.
Slide the brake and brake duct over the upper wishbone so that its tip enters the gap beneath the screw hole.
When it’s in place, tighten a screw C into the hole to secure it.
Slide the washer A onto the screw K.
Insert the screw through the hole in the forward-facing tip of the lower wishbone, and tighten. Be careful not to overtighten it.
Slide the silver end of the toelink through the notch in the quarter panel and into the right-hand toelink bracket, as shown.
Use a screw P to fix the toelink into position.
Stop turning the screw when its head touches the bracket.
Line up the free end of the toelink to the hole on the brake duct then use a screw M to fix these parts together. Again, tighten the screw only lightly.
Stage complete
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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 14 contains stages 47-49
Stage 47 contains: Underbody parts Middle, Underbody parts (L&R) Body mount Brackets A x4, Body mount brackets B x2 and assorted screws.
Mounting the engine oil tank
You will need the engine oil tank and gearbox assemblies from Stage 46, along with the length of hose B saved from Stage 44.
Prepare the hose B using instant adhesive as first explained in Stage 40, then cut off a 60mm length of it. Use a toothpick to make sure there is a small hole in each end of the 60mm length of hose.
Dab the indicated end of the oil line union on the side of the engine oil tank with instant adhesive. Push the end of the 60mm hose over this, and hold it in place for a minute.
Test-fit the engine oil tank onto the gearbox top by placing it into the indicated hole.
Check that the positioning of the part is exactly as shown in the photo, with the oil line union sitting at right-angles to the gearbox and the circled nozzle facing into the assembly.
Apply a small amount of instant adhesive to the indicated section of the engine oil tank lower, then place the part back onto the assembly as you did in the test fit.
Hold the part in place for a minute while the glue dries.
Mounting the underbody parts
Make sure you can identify the left and right parts.
Test-fit the left underbody part against the underbody middle’s inside rim, when facing upwards.
When you are happy with the fit, remove the part, apply some plastic adhesive to the area marked in red, and refit it.
Hold the part in position for two to three minutes while the adhesive dries. Repeat for the right underbody part.
Stage complete
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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 48 – Contains: Underbody Rear, Heat shield stickers x 2, Tailpipe endplate (L&R), Tailpipe endplate parts (L&R)
Adding the heat shield sticker to the underbody middle
Cut the sections marked below from one of the heat shield stickers. To do this, place the sticker, backing side up, on a cutting mat. Using a metal ruler and a pencil, measure and mark each section, then make the incisions carefully with a sharp knife. The sections should measure as follows:
Section A = 73 x 166mm;B = 8 x 80mm (x 2); C = 8 x 100mm (x 2); D = 8 x 20mm (x 2); E = 27 x 166mm. See image below.
Partly peel away the backing from one long edge of section A.
Lay the exposed backing on a cutting mat, then trim a 10mm-wide strip from it, as shown.
Lay the adhesive side of the sticker over the tip of the underbody middle, so that their edges align.
Running your finger from side to side to flatten the sticker, carefully pull the backing away.
When the whole sheet is stuck on, flatten the sticker around the two projections.
Trim away the sticker at these points to reveal the screw holes beneath it.
Cut along the inside edges of the ridges and remove the trimmed sections with tweezers.
Next, peel the backing away from one of the section Bs. Then run this along the inner side of the underbody rim: its upper edge should be flush with that of the rim, and it should begin at the same point as section A
Make sure there is no gap between the sections A and B.
The outer end of the section B should extend beyond the end of the underbody.
Trim the excess to match the edges of the underbody.
Use a cutter and tweezers to remove the area of the section B.
Repeat this step to apply the second section B to the opposite side of the underbody.
Fitting the heat shield to the underbody rear
Trace the diagram on the opposite page on a sheet of thin paper to create a template for the sticker that will cover the rear underbody, section F. Then use the template to outline the shape on the back of the second heat shield sticker sheet, as shown.
Cut out the section F, then peel one corner away and cut across the exposed backing paper.
Match the section F to the recessed section of the rear underbody, then stick the peeled-away corner in place. Make sure the longest edge of the sticker is aligned precisely with the ridge.
As you did for the section A in the previous step, flatten the free corner into place, then gradually peel away the backing and smooth the rest of the sticker out across the surface of the underbody.
Again as in the previous step, use your cutter and tweezers to remove the indicated strip of sticker and reveal the screw hole beneath it.
Now stick the first section C in place so it runs along the inside of the raised flange of the underbody.
Using the cutter, carefully trim the section C along the lines.
Remove the cut-away pieces with tweezers.
Now stick one of the section Ds along the end of one of the exhaust pipe spaces, lining up its edge to that of the plastic part
Smooth the section D into place, then repeat this step to apply the second section C and second section D and complete this stage.
Stage complete
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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 49 contains: Rear brake lines (L&R) Throttle links, connectors and cable tie tape.
Applying the heat shield sticker to the heat exchanger
You will need the heat exchanger saved from Stage 10, and the sticker section E (27 x 166mm) from Stage 48.
Peel one end of sticker section E away from its backing paper a little, then trim the backing with scissors, as shown.
Line up the exposed end of the section E with one edge of the heat exchanger, then press the sticker onto the surface of the part, smoothing it with your finger.
Pull tightly at the corner to ensure no ripples or creases appear.
Cut the sticker along the lower edge.
Turn the part over, and trim away the overhang seen at the two indicated corners of the part.
Mounting the tailpipe endplates and parts (R) and (L)
You will need both sets of tailpipe endplates and tailpipe endplate parts from Stage 48.
Lay both endplates next to each other on your work surface as shown. Each endplate will have its smaller hole set close to its inside edge.
Test-fit the parts by laying out the tailpipe endplate parts as shown to establish their final positions.
Scrape away the paint from the flat surface of the left tailpipe endplate parts.
Also scrape the paint from the underside of the left tailpipe endplate.
Apply some plastic adhesive to the left endplate parts, fit them to the left endplate, and hold them in place for three minutes.
Repeat for the right tailpipe endplate and parts. Leave both endplate assemblies to one side to dry for at least an hour.
Fitting the underbody middle and rear mount brackets
You will need the underbody middle and rear (Stages 47 and 48), the body mount brackets A (x 4) and B (x 2), and 6 screws R (all Stage 47).
Hold a body mount bracket A with tweezers and fit it into the slot on the underbody middle.
Hold the bracket in place with your finger, and, holding the underbody by its edge, tighten a screw R through the hole and into the bracket.
Repeat for the three remaining brackets A, which fit into the slots on the underbody middle.
Now use the same method to fit a body mount bracket B into the slot on the underbody rear.
Once again, make sure that the holes line up.
Holding the body mount B bracket in place, turn the assembly over and tighten a screw R through the hole and into the bracket.
Repeat for the second body mount bracket B and the slot in the opposite side of the underbody rear.
Mounting the heat exchanger
Run your finger across the heat shield sticker on the underbody middle.
Press down with your finger to form a small dent over each hole.
Pierce a small hole in each dent with a toothpick.
Now test-fit the heat exchanger by placing it onto the underbody middle.
When you are happy with the fit, dab the indicated points on the underside of the heat exchanger with instant adhesive and reattach the part. Hold it in place for one minute.
Fitting the tailpipe endplates
Test-fit the left tailpipe endplate assembly by fitting it into the indicated space on the underbody rear, as shown.
When you are happy with the fit, apply some plastic adhesive to the areas stripped of paint, then reattach the assembly and hold it in place for three minutes. Don’t apply too much adhesive, to avoid any squeezing out onto the underbody.
Repeat for the right tailpipe endplate assembly.
Stage complete
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