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 Rank: Super-Elite       Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 31
Contents: Front subframe base, front subframe right stay, front subframe left stay, screws.
Line up the front subframe base with the bottom of the main assembly, noting which way up it goes then drive a screw in to fix the left-hand mounting flange to
the main assembly and then into the right-hand flange.Moving to the top of the assembly, tighten a screw into both holes to secure the upper braces fitted in previous issues.
Take the left-hand stay, fitting its cranked end into the hole at the front of the subframe base and the mounting flange on the other end into the recess
on top of the main assembly, securing it through the flange with two screws.
Fit the fan assembly on top of the subframe, plugging the pin on the header tank into the hole and pressing it down firmly.
Fit both ends of the right stay in place as the left and secure with two screws as before.
Turn the assembly over, and use a screw to secure the cranked end of the left-hand stay. Repeat this for the right-hand stay.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.
Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 32
Contents: Steering rack assembly, steering column assembly, anti-roll bar, steering rack mounting, anti-roll bar links, rack mountings, anti-roll bar mountings, hoses, water pump, screws.
Take the anti-roll bar and its two links, fit one end of the anti-roll bar into the eye on the end of a link ensuring the pin on the link faces the anti-roll bar. Drive a screw into the end of the anti-roll bar to
secure the link. Repeat the process to fit the second link to the other end.
Offer up the anti-roll bar to the front of the subframe as shown. Fit the ends of the anti-roll bar into the triangles formed by the diagonal stays at the front of the subframe. Press the pin on the end of one link into the back of the
hole in the bottom wishbone and secure it from the front with a screw. Repeat this with the other link. Take one of the anti-roll bar mountings, using a pair of tweezers to hold it as shown, place it over the anti-roll bar, lining up the hole with the hole in the front subframe and secure it with a screw. Repeat this for the other anti-roll bar mount.
Take the steering rack mounting and press the pins on the underside of the mounting into the matching holes in the front subframe. Turn the assembly over, and taking the right-hand lower brace from Issue 2, .hold the steering rack mounting in place and fit the brace across the subframe so it mirrors the brace on the left. Then secure the end of the brace with a screw,followed by another screw to the adjacent hole, which helps to secure the steering rack mounting.
Feed the steering column assembly into the subframe and press the pinion gear on the end of the steering column into the steering rack mounting. Feed the steering rack assembly through the triangular braces at the front of the subframe so that the teeth on the rack will mesh with the pinion gear. Fit the end of the steering rack over the post on the steering upright and secure with a screw. Repeat this on the right hand side. Do not overtighten the screws, as the joints must be free to swivel with the steering.
Take one of the rack mountings, using a pair of tweezers to correctly position it over the rack, line up the two mounting holes with the holes in the front of the subframe and drive two screws in to secure it. Repeat this to fit the other mounting on the right-hand side. If you swivel one of the hubs left and right, the other will follow suit and the steering column will rotate.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 33
Contents: Radiator (front section), Radiator (back section), Cowl, Hose, screws
Start by taking the water pump and fitting the shorter hose from issue 32 onto the pin as shown.Fit the curved end of the longer hose to the other pin on the water pump.Making sure the hoses are facing in the right direction, slide the water pump behind the engine pulley ensuring the front of the engine now looks like this.
Align the engine with the rear of the front subframe. Keep the steering column out of the way against the side of the subframe, angled up above the engine mounting point.Carefully slide the engine into place, making sure that the longer hose fits through the front of the subframe below the fan and that the engine mounts line up with the mounting points on the underside of the subframe. Note
the angle of the steering column. Drive a screw into both engine mounts to secure the engine.Carefully apply a drop of superglue to the end of the top hose, and connect it up as shown.Take the oil filter from Issue 26 and glue the end onto the face of the oil pump.
Fit the top hose from Issue 30 between the expansion tank and the water outlet pipe above the inlet manifold. Loosely fit the four pins near the corners of the sump into the matching holes under the engine block to start with,so the batteries can be added later on. (The sump is a push-fit so you can change the batteries when necessary.)
Press the locating pins near the front ends of the torsion bars into the holes in the lower braces of the subframe and fit the end of the pipe running from the oil pump into the hole on the side of the sump.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 34
Contents: Bulkhead
Taking the parts provided with Issue 33,align the two pins on the cowl with the matching holes on the back of the radiator and press firmly together before driving screws into the holes in the radiator to fix the cowl in place.Line up the front of the radiator with the assembly and after pressing the parts together secure with two screws.Plug the end of the radiator hose into the hole on the side opposite to the lugs, noting the direction it faces.
Line up the two lugs with the matching holes in the bottom of the front subframe and fit the bottom hose from the water pump into the hole in the corner of the radiator.Move the radiator back into position until the top hose comes in line with the pin on the expansion tank then press the parts together and use two screws to secure the radiator to the subframe.
You can try test-fitting the subframe to the front of the bulkhead, but do not attempt to screw it in place. First, you need to add a number of ancillary systems to the bulkhead, which you will start in the next stage.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.Spal attached the following image(s):
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Rank: Super-Elite Groups: Registered
Joined: 19/06/2013 Posts: 4,588 Points: 13,553 Location: West Yorkshire
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Issue 35
Contents: Reservac tank (half), Reservac tank (half),Brake servo unit,Fluid reservoirs,Fuel filter,Clip,Brake hoses,Hydraulic and fuel pipes and Screws
Take the fuel filter and the wire clip, which fits into the two small holes and spring the clip into place. It is quite tight so you
may find it helps using a pair of long-nose pliers.Press the tab on the back of the filter into the matching
keyhole-shaped mounting hole on the bulkhead and secure it with a screw.
Take the two halves of the Reservac tank, match up the locating pin and arrowed hole, and press them together.Match up the two locating pins with the holes in the bulkhead, and having pressed the tank into position secure it with a screw.
Having matched up the bank of fluid reservoirs with the mounting holes in the bulkhead,press the pin into the matching hole and secure with a screw.Press the locating pin on the back of the brake servo unit into the hole next to the reservoirs and secure in place with a screw.
Take the fan of five pipes and holding the end black pipe with tweezers, push the tip into the hole shown in the reservoir. Now take the second black pipe and put it into the middle hole and the third pipe into the remaining hole.Fit the end of the shortest black pipe onto the pin projecting from the inner side of the fuel filter and the end of the white pipe over the pin projecting from
the opposite side of the fuel filter.
Using tweezers take the long arm of the ‘Y’ shaped brake hose and plug it into the hole in the Reservac and attach one of the short arms to the pin on the brake servo.
This issue is now complete. Store the assembly and any unused parts in an issue labelled bag.Spal attached the following image(s):
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