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Rank: Administration        Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 58
Air Filter
Parts supplied: Fuel tank lower, Fuel tank upper, Air filter tube, Air filter upper, Air filter lower, Air filter cover, Overflow tube and Screws BP04.Pic 1
Well, here we go with the first stage of Pack 7. The air filter will be constructed during this stage, for which a full schematic can be seen in Pic 2.
The fuel tank parts will be used in the next stage.
To begin pass the end of the air filter tube through the central opening of the air filter cover, making sure you align the notch and corresponding slot as shown in Pic 3.
Now mount the air filter upper onto the end of the air filter tube, also aligning the notch and slot as shown in Pic 4.
Next place the air filter lower onto the upper, aligning the notches as before and noting that the upper and lower parts can only go together in one position. Pic 5 shows the completed circular hole in the side of the filter canister.
With everything held in the correct position, secure the assembly with a BP04 screw, shown in Pic 6.
Finally, insert each end of the cover into the sides of the air filter lower section. Pic 7 shows the first tab correctly positioned, continue to fit the other two tabs in the same manner.
Stage complete Pic 8, carefully store any remaining parts in a stage labelled bag.delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 59
Left Rear Tyre
Parts supplied: Left rear tyre. Pic 1
In this stage we will construct and attach the fuel tank, a schematic of which can be seen in Pic 2.
To begin this stage, retrieve the two parts of the fuel tank, the overflow tube and the four BP04 screws supplied in the previous stage.
Start by mounting the overflow tube onto the right rear fender by pressing the two locating pins into the two holes (one at the base of the wheel arch and one at the top) carefully pressing the posts into the fender as far as they will go. Pic 3.
Next locate the two posts on the inside of the fuel tank upper (noting they are different heights) and can only be assembled with the lower half of the fuel tank in one way. Pic 4
Whilst holding the two parts of the fuel tank together secure the assembly with two BP04 screws as shown in Pic 5.
Now fit the posts on the underside of the tank into the holes in the chassis, as indicated in Pic 6 and then carefully turn the chassis over and secure the fuel tank to the chassis with two BP04 screws, shown in Pics 7 and 8.
Stage complete (Pic 9), carefully store any remaining parts in a stage labelled bag.delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 60
Left Rear wheel
Parts supplied: Wheel, Hubcap and Screw BD01. Pic 1
In this stage the left rear tyre/wheel is assembled, along with the brake backplate and drum. The wheel is attached and the hub cap connected. A schematic of this is shown in Pic 2.
To start, insert the wheel into the tyre as you have before as shown in Pic 3, then by lifting the wall of the tyre over the edge of the wheel on both sides make sure that the tyre is fitted around the wheel centre Pic 4. (Note , if this is difficult then place the tyre in fairly warm water to soften it and the task becomes a lot easier)
To make sure the tyre is centralised, roll the Tyre/Wheel assembly back and forth as indicated in Pic 5. This is done to check that the edges of the tyre are positioned correctly on both sides of the wheel.
Now retrieve the brake backplate and brake drum supplied with Stage 53, noting that the brake backplate is marked with the letter L. Fit the brake backplate as shown in Pic 6 and follow on by fitting the brake drum onto the rear left wheel axle as shown in Pic 7. (In doing so note the difference in hole sizes that the wheel locating pins will fit into).
Next fit the left rear wheel/tyre onto the axle, inserting the posts into the corresponding holes in the drum Pic 8 and secure the wheel with a BD01 screw as per Pic 9.
Finally mount the magnetic hubcap onto the wheel.
Stage complete Pic 10, carefully store any remaining parts in a stage labelled bag.
delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 61
Right Rear Tyre
Parts supplied: Right rear tyre. Pic 1
In this stage we fit the air filter and exhaust that were built in previous stages. A schematic can be seen in Pic 2.
Retrieve the exhaust and air filter assemblies from Stages 57 and 58. Pic 3
We will now fit the air filter onto the engine and in Pic 4 you can see the indicated mounting points. Insert the tube from the engine into the air filter. Then Insert the end of the air filter tube onto the carburettor. Pic 5
The next task is to fit the exhaust. In Pic 6, I have indicated all the connection points between the engine and exhaust to assist.
Now turn the chassis over and very carefully place the exhaust onto the underside of the engine by inserting the posts into the holes. Next insert the tubes coming from the engine into the holes of the exhaust. Pic 7
Stage complete Pic 8, carefully store any remaining parts in a stage labelled bag.
delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 62
Right Rear Wheel
Parts supplied: Wheel, Hubcap, Screw BD01. Pic 1
In this stage (a repeat of stage 60 almost) we will fit the right wheel this time to the rear chassis. A schematic is available to view in Pic 2.
Insert the wheel into the tyre as before Pic 3, then lift the wall of the tyre over the edge of the wheel and then turn the two around and repeat on the other side Pic 4. Roll the Tyre/Wheel assembly back and forth, to check that the edges of the tyre are positioned correctly on both sides of the wheel. Pic 5
Now retrieve the brake backplate and brake drum supplied with Stage 54, noting that the brake backplate is marked with the letter R. Then fit the brake backplate onto the axle Pic 6, making sure the locating pin fits in the rear of the backplate and then fit the brake drum onto the rear right wheel axle as per Pic 7.
Next fit the left rear wheel onto the axle Pic 8, inserting the posts into the corresponding holes in the drum and secure the wheel with a BD01 screw Pic 9.
Finally mount the hubcap onto the wheel.
Stage complete Pic 10, carefully store any remaining parts in a stage labelled bag.
delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 63
Central chassis
Parts supplied: Central chassis, Screws BD04. Pic 1
There is no construction for this stage  , but I`ve added a schematic showing the part orientation in Pic 2.
Stage complete, carefully store any remaining parts in a stage labelled bag.delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 64
Left Front Wheel Arch
Parts supplied: Left front wheel arch, Screw BD04. Pic 1
In this stage we will fit the left wheel arch (supplied with this stage) and the central chassis (supplied in the previous stage) to the rear chassis. There is a schematic showing the details in Pic 2.
To begin retrieve the central chassis and screws BD04 supplied with Stage 63. Pic 3
Insert the locating pin and post on the central chassis into the holes in the left front wheel arch and carefully press down on the wheel arch to properly engage the two parts Pic 4. Then secure the left front wheel arch to the central chassis with a BD04 screw Pic 5.
Next (for my own benefit), I laid the centre and rear chassis`s close to each other to see how the locating and fixing points lined up for the overlap as shown in Pic 6. I have indicated the overlap lines on the pic.
Now place the front of the rear chassis onto the rear of the central chassis and carefully press the two parts of the chassis together to properly engage their corresponding points, the locating pins of which are indicated in Pic 7.
Finally secure the two chassis parts with five BD04 screws at the points indicated in Pic 8.
Stage complete Pic 9, carefully store any remaining parts in a stage labelled bag.delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 65
Right front wheel Arch
Parts supplied: Right front wheel arch, Screw BD04. Pic 1
A small stage now to fit the right front wheel arch. A schematic of which is shown in Pic 2.
Locate the two holes in the rear of the right front wheel arch and identify the two posts on the front of the central chassis, noting that they are two different sizes that match the holes in the wheel arch.
Align the posts and holes of the wheel arch and central chassis and carefully press the wheel arch into place Pic 3. Then checking that the pin protrudes through the hole in the wheel arch, secure the wheel arch to the chassis with a BD04 screw Pic 4.
Stage complete Pic 5, carefully store any remaining parts in a stage labelled bag.
delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 66
Front Chassis
Parts supplied: Front chassis, Screws BD04 and BP10. Pic 1
In this stage we will fit the front chassis, which in turn will support and strengthen the front wheel arches. A schematic for this can be seen in Pic 2.
Locate the seven indicated holes in the front chassis Pic 3 and the seven corresponding posts on the central chassis and wheel arches. Pic 4
Now place the front chassis onto the central chassis and press the front chassis into place, making sure the seven posts engage fully with the seven holes. Pic 5
Then secure the rear of the front chassis to the central chassis with three BD04 screws Pic 6 and the sides of the front chassis to the wheel arches with four BP10 screws. Pic 7
Stage complete Pic 8, carefully store any remaining parts in a stage labelled bag.delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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Rank: Administration Groups: Registered, Forum Support Team, Administrators, Global Forum Support Team, Moderator, Official Builds Joined: 09/11/2012 Posts: 8,292 Points: 23,964 Location: East midlands
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Stage 67
Lower Front Chassis
Parts supplied: Front chassis lower, Screws BD04. Pic 1
In the final stage of this pack, we will fit the lower front chassis to the upper. A schematic of this can be seen in Pic 2.
Start by locating the six posts on the front chassis lower Pic 3 and the six corresponding holes in the front chassis Pic 4, noting that the front chassis lower is designed to fit with the chassis in only one way.
Now turn the main chassis upside down, check the orientation of the lower chassis to the upper Pic 5 and mount the front chassis lower onto the front chassis and then carefully press the parts together, making sure all the pins enter their relevant holes. Pic 6
Holding the parts together, carefully turn the assembly over and secure the front chassis lower with six BD04 screws as shown in Pic 7.
Stage complete Pic 8, carefully store any remaining parts in a stage labelled bag.
Pack 7 is now complete, so see you soon for pack 8. delboy271155 attached the following image(s): COME BACK GUY FAWKES "YOUR COUNTRY NEEDS YOU"
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