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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 19 contains Stages 61 - 64
Stage 61 – The windscreen
Contains –
Roof and windscreen frame
2 × 5mm countersunk screws × 5
Place a cloth or towel on your work surface and lay the windscreen from Stage 60 onto it. Locate the mounting pins around the edge of the windscreen and the mounting posts in the corners.
Place the roof and windscreen frame onto the towel or cloth and align the pins of the windscreen with the holes in the frame then lower the windscreen onto the frame and press down to push the pins into the holes.
Turn the assembly over and insert four 2 × 5mm countersunk screws into the holes, half tighten them at first then tighten all the way in the order sugested in the instructions.
This stage is now complete. Store the roof and windscreen assembly in the packaging in which this stage’s parts were supplied to avoid damaging it.
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 62 – The roof lining
Contains –
Roof lining
Periscope window
2.6 × 6mm screws × 3
2 × 4mm countersunk screws ×7
Align the holes of the roof lining with those in the posts of the roof and the windscreen frame then lower the roof lining into place, keeping the holes aligned. Insert a 2 × 4mm screw into the indicated hole in the
roof lining and half tighten, then half tighten five more 2 × 4mm screws into the holes in the roof lining. Once they are all in place, fully tighten them into the holes.
Align the inner holes of the rear body support (Stage 58) with the posts on the underside of the roof, lower into place and secure with two 2.6x6mm screws.
This stage is now complete. Store the assembly upside down to avoid damaging the roof liner.
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 63 – The boot cover lining
Contains –
Boot cover lining
Boot cover lining stay
2 × 4mm screws × 3
1.7 × 4mm screws × 2
Prepare the boot cover lining stay. You will notice that it extends like a telescope. Place the boot cover lining with the inside (black side) facing up. Hold the stay next to it, with the thinner end nearer the lining and the open side facing up.
Insert a 1.7 × 4mm screw into the hole at the end of the stay and tighten into the hole in the boot liner, pivot the stay on its hinge. If it is too loose, tighten the screw a little more; if it is too tight, try loosening the screw.
After adjusting the screw, test the telescopic extension of the stay. If it is too loose, wrap some tissue around it and lightly squeeze with pliers.
Stage complete.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 64
The tail panel
Contains -
Tail panel
Tail lamp LEDs × 2
LED stoppers × 2
2.6 × 6mm screws x 19
Remove the battery box cover, and insert the three AAA batteries into the box then replace the cover.
Insert the battery box connector into the socket labelled ‘BATTERY’ on the LED tester, then insert one of the tail lamp LEDs into the socket labelled ‘LED1’. The LED at the end of the cable should illuminate when the connector is plugged in. Test both tail lamp LEDs.
Hold the left rear wheel box and align one of the LEDs with the hole, Insert the LED into the hole, and push the cable down so that it is flat against the inside of the wheel box. Align the two pins on one of the LED stoppers with the holes on either side of the LED then push the stopper into place.
*If the pins don’t fit into the holes, enlarge the holes with a needle file. Test-fit the stopper as you go, so you don’t enlarge the holes too much*
Align the pin and post of the tail panel with the corresponding holes in the right rear wheel box and push into place then secure with a 2.6x6mm screw.
Insert the pin at the side of the boot cover lining into the hole in the inner edge of the wheel box. Lift the boot cover lining up and fit it into place against the top of the tail panel.
Prepare the left rear wheel box. As with the right box, you will need to align the screw hole in the tail panel with the hole in the end of the wheel box, and insert the pin of the boot cover lining into the hole in the inner edge of the wheel box.
Secure the left wheel box to the tail panel with another 2.6x6mm screw.
This stage is now complete. Store the assembly carefully, as it is held together by only two screws at the moment.
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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Pack 20 contains Stages 65 - 67
Stage 65 – The chassis
Contains –
Chassis
2.6 × 3mm screws with washers × 7
2.3 × 5mm screws × 3
2.6 × 6mm tapping screws × 3
Plaque
Check the words on the plaque to confirm which edge is the top. There is a protective film over the front and double-sided tape on the back.
Remove the double-sided tape from the back of the plaque then hold the plaque at the edges and peel the protective film from the front.
Place the plaque on the chassis with the top edge facing inwards and press it onto the chassis.
Wipe the surface of the plaque with a soft cloth. The surface of the plaque will easily pick up dirt and grease, so try to avoid touching it with your fingers.
This stage is complete. Store the chassis away until a later stage.
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 66 – The boot liner
Contains –
Boot liner
Boot lock
Peel the double-sided tape from between the two pins on the back of the boot lock.
Locate the two mounting holes in the back edge of the boot liner then align the pins on the lock with the holes in the liner. Insert the pins of the lock into the holes in the edge of the liner and press the lock down into place.
This stage is now complete. Store the boot liner in a closed plastic bag until it’s needed again, because its flocked surface will easily pick up dust and dirt.
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 67 – The left headlamp and lenses
Contains –
Left headlamp unit
Headlamp lens A
Headlamp lens B
Remove the battery box cover and insert three AAA batteries into the box.
Connect the battery box to the ‘BATTERY’ socket on the LED tester. Align the connector at the end of the cable from the left headlamp unit with the socket labelled ‘LED1’, then insert the connector into the socket.
This should illuminate the one of the lights of the left headlamp, repeat for the other connector to illuminate the other light. Once tested, remove the connectors from the sockets, and the batteries from the battery box.
Look inside each headlamp reflector and locate the stepped lip. There is a step around the rim of each headlamp lens (A and B), which matches the stepped lip in each of the reflectors.
Apply a small strip of masking tape to each side of the headlamp in line with the steps in the reflectors, then apply a strip of masking tape to the upper half of each lens, in line with the step.
Place headlamp lens A into the headlamp reflector then fit lens B into position. The lenses should both fit snugly into place.
This stage is now complete. Keep the headlamp unit safe until it is required later in the build.
stevie_o attached the following image(s):
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