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Issue/Stage 69 Contains – Wing Mechanism Support, End Brace, Wing Pivot Rods (x4), XW08 Screws (x6).
Assembling the Rear Fuselage
Take the rear fuselage base from Stage 66, plus the parts provided this time, except for the metal pivots which are fitted later.
Take the end brace and line up its two fixing pins with the holes in the end of the wing mechanism support, pressing the brace into place until it fits flush. Fit the wing mechanism support into the rear fuselage base as shown, taking care not to trap the loose wires between the parts, fitting it all the way into the base.
Now fix the support in place using five XW08 screws as shown.
This issue/stage is now complete. Store any remaining parts in a stage labelled bag.
Markwarren attached the following image(s):
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Issue/Stage 70 Contains – Gearbox Cover, Gearbox Casing, Motor Mount, Droid Actuator, Contact Housing, Contact Cover, Actuating Gear, Reduction Gears (x3), Driving Pinion, Spindle, Electric Motor, Microswitch, Droid Contacts, Contact Springs (x2), XW08 Screws (x8), XW09 Screws (x3), XW10 Screws (x2).
Assembling the Gearbox
Take the gearbox casing and covers, actuating gear, three reduction gears and spindle, plus four XW08 screws. Start with the actuating gear, which goes in with the smaller gear first. Fit the spindle that runs through the gear into the hole in the casing as shown, pressing the gear all the way in until it comes out the other side of the casing. Place the spindle into the hole next to the actuating gear and press it all the way in. Take the first of the three reduction gears which goes on the smaller gear first. Fit the gear all the way down the spindle so it meshes with the actuating gear. Take the second reduction gear and place it on the spindle of the actuating gear with the smaller gear first. Again, press all the way down so it meshes with the previous gear as before. Now take the final reduction gear and place it on the spindle as shown.
Take the cover, noting which way round it goes and fit the ends of the spindles in the two holes, not the larger hole between them. Carefully fit the cover over the spindles and press the cover into the casing, making sure the cover fits flush all round. Secure the case using four XW08 screws.
Fitting the Motor
Take the parts shown for this stage, the gearbox assembly, electric motor, driving pinion, mount, screw, and droid actuator. Start with the electric motor and the small driving pinion. Fit the pinion into the end of the shaft and press it firmly onto the work surface. Use pliers or similar to push the pinion further along the motor shaft as shown. Ensure you leave a slight gap to avoid the pinion jamming or straining the motor. Fit the motor into the housing in the gearbox as shown. Make sure the pinion meshes with the reduction gear, so you can push the motor all the way in. Fit the motor mount over the wires leading from the motor, so you can slip the slot in the end of the motor mount over the tab projecting from the gearbox. Make sure the hole on the underside of the motor mount fits over the hole in the gearbox. Secure the motor mount with an XW08 screw. Take the droid actuator, which fits onto the projecting shaft of the actuating gear and goes this way round as shown. Line up the hole with the shaft making sure that the projecting arm is in line with the end of the gearbox and press the actuator firmly into place.
Fitting the Electronics
Take the assembly together with the micro switch and its wiring. Line up the micro switch next to the droid actuator, this way round. Press the two holes in the body of the switch into the two pins on the gearbox until the switch fits flush. The assembly should look like this as shown.
Take the droid contacts, housing, and cover, plus an XW10 screw. Note the “+” and “- “markings inside the contact housing. These show which of the contacts fit into the holes next to them. Start with the wire with minus printed on the tag near the end. Handle it with care, press it all the way into the hole marked minus with the wire leading down as shown. Now fit the wire with the plus printed on the tag into the hole marked plus. Take the wires down through the notch in the side of the housing, as shown. Line up the cover, noting the moulding on the inside needs to fit over the two contacts. Fit the cover into the housing so it goes flush and secure it with an XW10 screw.
Take the assembly, together with the gearbox. Take one of the springs, which fits over the two posts indicated. Slip a spring onto each of the posts and line up the contact housing with the two posts, as shown. Press the contact housing into place, compressing it against the spring pressure. Be careful not to release the housing, or you may lose a spring. Secure it to the post with two XW09 screws.
This issue/stage is now complete. Store any remaining parts in a stage labelled bag.
Markwarren attached the following image(s):
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Issue/Stage 71 Contains – Base Frame, Lower Rear Frame, Right Side Frame, Left Side Frame, Main Power Switch, Lower Mid Frame, XW01 Screws (x3)
Preparing the Wing
Take each of the four wing assemblies in turn. You need to remove the laser cannon barrel at this point, including the laser cannon front end cap. Slide the cap off the laser generator and lift the whole barrel assembly away making sure the fibre optic cable stays in place inside the barrel. Put the barrel carefully to one side, then repeat for the other three wings. For the next part of the assembly, you will need all four wings, the circuit board from issue 67, wing drive motor and gearbox from stage 68, plus the wing mechanism support, four wing spindles and six XW08 screws from issue 69.
IMPORTANT NOTICE
It has been found that the motor can over run when the wings close which may cause an issue with the gears. This is because the wings have a slight curvature and do not lie flat on top of each other, so the tab for stopping the motor does not come to the limit switch. Before proceeding with the assembly of the wings you will need to attach a small piece of plastic card to the lower tab of the right lower wing assembly as shown in the picture below. I would advise this tab is in place before proceeding with any of the next steps.
Connecting the Electronics
Take the wing mechanism support, which has the switches on it. Their leads are numbered 13 and 14. Hold the circuit board as shown. Plug the lead marked 14 into the matching socket. This connects the switch that detects when the wings are fully open. Plug the lead labelled 13 into the matching socket. This connects the switch that detects when the wings are fully closed. Placed the lower port wing alongside the wing mechanism support, ready to connect its wiring. Plug lead 3 into the matching socket. This connects the laser cannon light. Plug lead 4 into the matching socket. This connects the engine light. Place the lower starboard wing alongside the rear fuselage and plug lead 5 into the matching socket. This connects the starboard wings laser cannon light. Plug lead 6 into the matching socket. This connects the starboard engine light.
Lay the upper port wing on top of the lower port wing. Plug lead 7 into the matching socket, this connects the laser cannon light. Plug lead 8 into the matching socket, this connects the engine light. Lay the upper starboard wing on top of the lower starboard wing. Plug lead 1 into the matching socket, this connects the laser cannon light. Plug lead 2 into the matching socket, this connects the engine light. Now take the wing motor and gearbox assembly and plug its leads (labelled 18) into the matching socket. fit the board into the housing in the rear fuselage and carefully secure with two XW08 screws as shown.
Fit the wing motor and gearbox assembly into the rear of the fuselage as shown, lining up the mounting holes on each side, so you can secure it as shown. Fix the base of the gearbox with XW08 screws into the two holes as shown.
Fitting the Wings
Slide the lower port wing into the fuselage so that the gear teeth moulded on the rear corner mesh with the white drive gear on the gearbox and the pivot holes line up with the holes as shown. Take a spindle and fit the pointed end first through the rear pivot hole, all the way through the wing, and into the front pivot hole to the lock the wing in place. Slide the lower starboard wing across to bring gears into mesh as shown. Note: The wings must mesh as shown, with two teeth on the port gear visible above the starboard gear. Use another spindle to lock the starboard wing, in the same way as the port. Slide the upper port wing across the lower port wing, keeping the interfaces together. Mesh the gears and line up the pivot hole. Insert another spindle all the way through, to lock the wing in place. Slide the upper starboard wing over until the gears mesh and the holes line up. Insert the last spindle to lock it in place.
This issue/stage is now complete. Store any remaining parts in a stage labelled bag.
Markwarren attached the following image(s):
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Issue/Stage 72 Contains – Lower Front Frame, Left and Right Base Struts, Left and Right Side Struts, XW01 Screws (x8), XW02 Screws (x6).
Note: In this issue, the magazine prepares you to start testing the electronics as well as the wing operation. Under no circumstance are you to test the electronics at this stage. These will be tested in stage 74 when the mains cable is supplied and fitted. The full instruction on how to test them will be made in stage 74.
This issue/stage is now complete. Store any remaining parts in a stage labelled bag.
Markwarren attached the following image(s):
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