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 Rank: Super-Elite        Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Pack 9 contains Stages 48 – 53
Stage 48 – Rear Hub Carrier
Parts supplied:
Outer ball bearing
Rear hub carrier
Inner ball bearing
Threaded plugs
Ball-headed screws
With this stage, you have received the components that make up the second of the two rear hub carriers. These parts are the same as those you received with Stage 26. If you have already started to assemble the rear suspension, you will have fitted the previously supplied rear hub carrier to the right-hand side, so fit this hub carrier to the other side.
In addition to the parts received with this stage, you will need a 5mm Allen key.
Insert the two ball-headed screws into the two lower holes of the hub carrier. The two threaded plugs each have a flat end and a slightly concave end, insert the Allen key into the flat end of one of the plugs and screw the plug into one of the two lower holes of the hub carrier, from the opposite side to the ball-headed screw, then repeat the process to insert the second plug into the other lower hole. Test that the ball-headed screws can still move freely, and loosen the plugs slightly if they can’t.
Finally, insert the two different sized bearings into the corresponding holes in the hub carrier.
Stage 48 complete.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 49 – Glow plug and head shims
Parts supplied:
Glow plug
2.5 x 6mm screws
Head shims
Self-locking nuts
3 x 8mm screws
The eight 3 x 8mm screws supplied with this stage will secure the two servos to the servo mount. The other screws and self-locking nuts that were supplied will be used in future assembly stages. The other parts are the glow plug, with its copper washer, and the two shims, which are each just 0.14mm thick and will be fitted under the cylinder head.
There is no assembly work to do in this stage, so store all the parts safely until they are needed later on.stevie_o attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 50 – Rear driveshaft and stub axle.
Parts supplied:
Rear driveshaft
Stub axle
Drive pin
Hexagonal drive washer
Flanged nut
The driveshaft, stub axle and other parts supplied with this stage are interchangeable with those received in Stages 21 and 36. If you’ve been working through the assembly sequence, use this set of parts for the left rear wheel, as you will have used the other sets for the right rear and left front wheels.
As well as the parts supplied with this stage, you will need the left rear lower arm, supplied with Stage 19, and the left rear hub carrier assembly from Stage 48, you will also need a 2.5mm Allen key and a 5.5mm cross wrench.
Insert the ends of the ball-headed screws in the rear hub carrier into the holes in the lower arm, and start to screw them in.
Now slowly screw them into the holes, working on them alternately, the screws do not need to go all the way into the lower arm – some of the thread should still be exposed.
Insert the stub axle into the hub carrier, and then insert the drive pin into the hole in the axle. Place the drive washer onto the stub axle, fitting the recess over the drive pin, and then tighten the flanged nut onto the end of the axle.
Insert one end of the driveshaft into the stub axle, and either use an elastic band to hold it in place or store the parts together in a labelled plastic bag.
Stage 50 complete.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 51 – Servo and servo horn.
Parts supplied:
Servo
Servo horn
The parts supplied with this stage are your model’s second servo and its horn. This servo is the same as the one provided with Stage 43, and because these servos are the same, they are interchangeable up until they are fitted, at which point one becomes the steering servo and the other the throttle/brake servo.
There is no assembly for this stage so just store the parts for use later in the build.
Stage 51 completestevie_o attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 52 – The bodyshell.
Parts supplied:
Bodyshell
The component supplied with this stage is the racing bodyshell of your Huracán, which will be completed by the addition of the front and rear bumpers received with Stages 1 and 2. In this stage, you begin preparing the bodyshell so that it can be fitted to the model.
As well as the bodyshell, you will need a large pair of scissors, a smaller pair of curved scissors, a reamer and some wet and dry paper.
Before you begin, locate the cutting lines around the bodyshell, the bodyshell is covered in a protective film, but do not remove it yet.
There are four points on the bodyshell that need to be pierced, two on the front and two on the rear.
Using large scissors, cut away the excess plastic from around the base of the bodyshell. Use the reamer to begin opening one of the four holes, taking care not to force it in too hard. Make the holes slightly smaller than their outlines.
After opening each hole, turn the bodyshell over and gently ream the hole from the inside. This is not to enlarge it, but to smooth it and remove any burrs or roughness.
Once you’ve made the holes, cut along the lines identified previously, use small but sharp curved scissors to ensure that you can cut along the lines as neatly and accurately as possible.
Using wet and dry paper, carefully sand away any excess from the cut edges of the bodyshell. Make sure that you follow the lines, and take care not to apply too much force to it.
After you’ve finished sanding with wet and dry paper the wheel arches should have a smoothly curved edge, without any burrs or roughness.
Finish off the rest of the bodyshell in the same way.
Stage 52 complete.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 53 – Cylinder head and head covers
Parts supplied:
Head covers
Cylinder head
2.5x12mm screws
This stage’s parts are for your Huracán’s engine. The largest piece is the cylinder head, which closes the top of the cylinder to complete the combustion chamber. The two smaller parts are the head covers, which will be mounted on top of the head. They not only replicate the head covers of the real car, but also dissipate the heat generated when the engine is running.
You will need the cylinder head and head covers, plus two of the eight 2.5 x 12mm screws supplied with this stage and the glow plug from Stage 49, you will also need a 2mm Allen key, either straight or L shaped, and an 8mm socket wrench.
Locate the holes in the undersides of the head covers. These will align with corresponding holes in the cylinder head, which will be where the screws will fit to hold the parts together.
Check that the copper washer is still in position on the glow plug. Then place the glow plug into the end of the socket wrench and tighten it into the top of the cylinder head.
Fit the left head cover onto the top of the cylinder head, aligning the holes and the sides of both parts. Tighten one of the two 2.5 x 12mm screws into the hole to secure the head cover.
Repeat this process to fit the right head cover to the top of the cylinder head. Although the head covers are secured to the head, they will still be able to rotate, because they are each held by only one screw.
This will allow you to swing them aside to access the holes for the four screws that will fix the head to the cylinder.
Stage 53 complete.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Pack 10 contains Stages 54 – 59
Stage 54 – Piston, connecting rod and cylinder liner
Parts supplied:
Piston with connecting rod
Cylinder liner
The parts supplied with this stage are the cylinder liner and the pre-assembled piston and connecting rod, which are three of the most vital elements of your Huracán’s engine.
You will fit them into the main engine assembly in Stage 57.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 55 – The Crankcase
Parts supplied:
Crankcase assembly
Carburettor attaching screw
The components for Stage 55 are the crankcase and the carburettor attaching screw. The crankcase is the main block of the engine, to which all the other parts will be fitted, and is pre-fitted with two ball bearings that will carry the crankshaft.
The carburettor attaching screw and its retaining nut are not used until the next stage, but they are quite small, so either fit them loosely in place or keep them safely in a labelled bag until you need them.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 56 – The carburettor.
Parts supplied:
Carburettor
O-ring
With this stage, you receive another important part of the engine – the carburettor – along with the O-ring that will create an airtight seal between it and the crankcase.
Now you will begin the assembly of your engine by fitting the carburettor to the crankcase.
In addition to the carburettor, you will need the parts from the previous stage – the crankcase and the carburettor attaching screw. The only tool required for this stage is a 7mm socket wrench, which you will need when you tighten the carburettor attaching screw’s retaining nut.
Fit the O-ring over the bottom port of the carburettor, and push it up against the body of the carb. Before fitting the carburettor to the crankcase, you will need to adjust the position of the recess in the carburettor attaching screw to match the inside of the carburettor mount.
Place the carburettor into its mount, now tighten the carburettor attaching screw nut to secure the carburettor to the mount.
Note that the correct orientation of the carburettor is shown in the photos below and in the final photo of the stage 10 instructions.
Stage 56 complete.
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 57 – The Crankshaft.
Parts supplied:
Crankshaft
Tapered collet
The parts provided with this stage are the crankshaft and a tapered collet, which allow you to complete the main assembly of your Huracán’s engine. Before you begin, it is recommended that you remove the two head covers, fitted in Stage 53, for ease of assembly.
You will need the crankcase and carburettor assembly from Stage 56, the cylinder head, covers and screws from Stage 53, the two shims from Stage 49, and the parts from Stage 54. You will also need a 2mm Allen key and some lubricating oil.
Insert the crankshaft into the crankcase, Its shank should pass through the two bearings inside the crankcase.
Keep pushing the crankshaft into the crankcase until the end of the shank comes out of the case below the carburettor. Hold the piston with the connecting rod then lower the rod and piston into the crankcase. You must make sure that the lubrication hole is on the carburettor side of the crankcase.
Now rotate the crankshaft until its pin lines up with the hole in the big end of the connecting rod. Carefully move the crankshaft pin and the big end until they are fully aligned, and then push the big end onto the pin.
Apply a drop of oil to the two parts to prevent any friction between them, which would damage the bush inside the big end.
Now insert the cylinder liner into the crankcase. Before you do so, make sure that you align the notch on the liner with the pin on the crankcase.
The cylinder liner will enter the crankcase more easily if you spread a thin film of lubricating oil around it. Remove any excess oil with a paper towel. Lower the cylinder liner into the crankcase until it is a little less than halfway in, then rotate the crankshaft to push the piston up into the liner.
Be careful when pushing the piston into the cylinder liner, as the fit between them is very tight. If they get stuck, apply a little lubricating oil to the inside of the liner, and work slowly to push the liner fully into the crankcase.
Fit the two shims from Stage 49 on the underside of the cylinder head, a few drops of oil on the shims will help to keep them in place.
Align the four holes in the cylinder head with those in the top of the crankcase then insert four of the screws supplied with Stage 53 into the aligned holes, and half-tighten them into place.
Fully tighten the four screws into their holes, screwing each one in by a few turns at a time until they are all fully tightened. Use a crossover sequence: starting with any one of them, tighten it, and then tighten the screw diagonally opposite it. Then tighten the other two screws.
Place the head covers into position and align the holes in them with those in the cylinder head. Insert the remaining four screws into the holes in the underside of the head to fix the covers to it (see Stage 53).
Tighten the four screws into place to secure the covers, then place the tapered collet onto the end of the crankshaft.
Push the collet along the shaft until it butts up against the bearing.
Store the assembly safely until you need it again.
Stage 57 complete
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 58 – The Starter Rear Plate.
Parts supplied:
Starter rear plate
Screws 2.5 x 7mm
Starter gasket
The components supplied with this stage are more parts of the engine. The starter rear plate closes the end of the crankcase into which the crankshaft was inserted, and the gasket fits between the plate and the case. The recoil starter then fits onto the outer face of the plate. You will notice that the inner face has a raised cylindrical section. This is to reduce the volume inside the crankcase slightly, and the cutaway part of the section is to keep it clear of the piston and the cylinder liner.
The gasket will ensure an airtight seal once the plate is secured with the four screws. Keep these parts safely to one side until the following stage, when they will be fitted to the engine along with the rest of the starter system.stevie_o attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 30/01/2013 Posts: 4,604 Points: 13,607 Location: Monmouthshire UK
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Stage 59 – The Recoil Starter
Parts supplied:
Recoil starter
One-way bearing and housing
Recoil starter shaft
Screws 2.5 x 8mm
The components supplied with this stage make up the recoil starter, with which you start the engine of your Huracán. When you have fitted these new parts, your engine will be almost complete.
In addition to the components provided with this stage, you will need a Phillips screwdriver and the parts from Stage 58.
The recoil starter shaft will fit into the hole in the centre of the starter rear plate, Do not fit it yet.
Locate the end of the crankshaft, inside the crankcase. Insert the recoil starter shaft into the crankcase, placing the cutout over the end of the crankshaft.
Place the gasket onto the starter rear plate. You may find it easier to fit it if you push one of the screws through one of the holes in the plate. Fit the rear plate onto the crankcase, passing the starter shaft through the hole in the centre of the plate. Align the plate and the four screw holes with those in the crankcase.
Insert the four 2.5 x 7mm screws from Stage 58 into the holes and tighten them gradually, in a crossover sequence, until they are all secured, now fit the one-way bearing onto the starter shaft. Make sure that the exposed (silver) end of the bearing is closest to the crankcase. The bearing must turn anticlockwise.
Place the recoil starter onto the bearing housing then rotate the starter so that the four holes in the corners line up with those in the rear plate, then tighten a 2.5 x 8mm screw into each of the holes, again in a crossover sequence. Do not overtighten the screws, because this can damage the plastic.
This stage is now complete, and your engine is one step closer to being finished.
Stage 59 complete.stevie_o attached the following image(s):
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