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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 76
Contents: Stone guard frame, Stone guard mesh, Screws
Note The instructions below refer to the correct screw types to be used in steps 3 and 5.
Align the mesh with the rectangular recess in the frame.Fit the mesh into the recess so that its four corner holes align with those of the frame.Screw the mesh to the frame with four JD10 screws – one
in each corner.Slide the stone guard down into the slot at the front of the bonnet and secure it using two JP01 screws.
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 77
Contents: Front underpanel, Screws
Note The Parts identification list incorrectly labels the screws, JD01 are the shorter screws and JD11 the longer.
Take the underpanel, and align it with the bonnet assembly from Stage 76. Fit the lug on the underpanel over the mounting hole beside the stone guard and secure the lug with a screw. Repeat this on the opposite side.Secure the lugs at the front left and right of the underpanel using screws.
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 78
Contents: Wheel rim (outer), Inner spokes x 24
There is no assembly to be done at this 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 79
Contents: Wheel centre,Inner spokes x 24, Spoke retainer ring,Screws
Note: Those that made the spare wheel using the 2-spoke cross over method should continue to use that method for the rest of the
wheels, and those that did the 3- spoke experienced method should continue to use that method. The official build will follow the experienced build method.
Take the wheel centre and fit it onto the wheel building jig with the smaller diameter flange first. Note that the hole in the centre has a slot that engages with a matching tab on the jig to lock it in one position. Fit the outer wheel rim onto the wheel building jig so that the hole in the outer flange fits over the matching pin on one arm of the jig, locking the rim in position. Press the rim down between the four arms.
To keep the spokes in place during assembly carefully cut a strip of double sided tape measuring about 1.5-2mm wide and 160mm long. Using a cocktail stick or something similar, work the strip of double sided tape right down into the groove all around the rim, then peel off the backing strip to reveal the adhesive layer.
Each of the spokes has a pinhead on one end, this will lock the spokes into the wheel centre. The spokes also have two bends so that they will fit at the correct angle. Fit a spoke through one of the lower row of holes in the wheel centre and pull it through until the cranked end reaches the groove around the rim. The length and angle of the spoke means it will only fit snugly into one of the angled grooves around the rim. Lay the cranked end in whichever groove it reaches and press the tip down into the double sided tape. Then fit another spoke through the next one of the lower row of holes in the wheel centre, fitting as you did previously and laying the end into the next but one notch in the rim, stick the tip down.
Repeat the process until you have fitted 24 spokes into the alternate holes all the way round the rim, the whole of the lower row of holes in the wheel centre will have spokes fitted into them.
Take another spoke and fit it into one of the upper holes in the wheel centre, angling it in the opposite way to the first set of spokes. Work around the upper row of holes in the wheel centre, taking each spoke in turn to the next notch in the rim. Repeat the process until you have fitted 24 spokes into the alternate holes all the way round the rim. The tips of all 48 spokes should all be sitting in the grooves around the rim, angled in alternate directions.
Take the spoke retainer ring which has an array of notches that match the ones in the rim and four projecting tabs with holes for screws, which will go into the holes on the outer wheel rim. Making sure you do not dislodge any of the spokes from their notches, invert the retainer ring over the rim so that the four tabs match up with the holes and the notches fit over the spokes. Insert screws into each of the four holes and tighten them to lock the retainer ring in place, then pull the wheel building jig away to release the part build wheel. You will fit the inner rim and remaining 24 spokes later on.
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 80
Contents: Outer spokes (Type A) x 12, Outer spokes (Type B) x 12, Wheel rim (inner), Spacer ring, Screws
Take all the parts supplied this time together with the wheel assembly you completed in Issue 79. Cut a strip of double sided tape measuring about 1.5-2mm wide and 160mm long. Lay this in the groove that retains the ends of the spokes. Work the strip of double sided tape right down into the groove all around the rim then peel off the backing strip to reveal the adhesive layer.
Start by taking one of the spokes from the packet labelled ‘A’. Fit it through one of the lower row of holes in the wheel centre and thread the cranked end down through the ‘V’ formed by the closest pair of inner spokes. Turn the wheel over and lay the end of the spoke into the angled groove in the rim (it will only reach one). Press the cranked end of the spoke down into the double-sided tape to hold it in position.
Now take a spoke from packet ‘B’. Fit it through the upper row of holes in the wheel centre, using the hole above and to the left of the one fitted previously. Take the cranked end across the spoke you just fitted and down through the ‘V’ of the next pair of inner spokes. Turn the wheel over and lay the end of the spoke into the next angled groove in the rim, with its cranked end pointing towards the end of the first spoke you fitted. Press it into the double-sided tape to hold it in position.
Take another spoke from packet ‘A’. Fit it through the next one of the lower row of holes in the wheel centre and then down between the next pair of inner spokes. Turn the wheel over and lay the end of the spoke into the next notch in the rim, sticking the tip down as you’ve done previously. Take another spoke from packet ‘B’. Fit it through the hole above and to the left of the one fitted previously, across the spoke you just fitted and down through the ‘V’ of the next two inner spokes, secure the end to the rim.
Continue working round the wheel centre, alternating ‘A’ and ‘B’ spokes, crossing them over and feeding the tips through successive pairs of inner spokes. Repeat the process until you have fitted all 24 spokes into the alternate holes all the way round the rim. All the ends of the spokes should be lying in the groove around the rim.
Take the spacer ring and align the hole with the pin projecting from the wheel rim. Fit the spacer ring over the ends of the spokes then align the pin with the hole in the inner wheel rim. Press the inner wheel rim into place which will align the four screw holes. Drive a screw into each of the holes to complete the wheel.
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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