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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 27A:
Brake and clutch cylinders.
Pic 1: Press-fit the brake cylinders 27F to the frame 26A as shown.
Pic 2: Locate the brake and clutch lever parts 2 x 27C and 2 x 27E.
Fit the parts together and fix using 1 x MP screw in each.
Pic 3: Fit the rod 27E into the hole on the base of the brake cylinder and position the lever 27C as shown.
Fit the cap 27D over the top and secure with 1 x ABM screw.
Pic 4: Press-fit the clutch cylinder 27G in place on the frame as shown.
Pic 5: Fit the rod 27E into the hole on the base of the clutch cylinder and position the lever 27C as shown.
Fit the cap 27D over the top and secure with 1 x ABM screw.
Pic 6: Fit the two covers 27B as shown and secure with 2 x AM screws in each.
Pic 7: Locate the tube 27K and cut off three lengths – 20mm, 70mm and 120mm.
Fit them to the union 27J as shown.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 27B:
Pic 8: Fit the union to the frame next to the brake cylinders and fix from behind with 1 x AP screw.
Pic 9: Press-fit the wiper motor parts 27H and 27I together. They will only fit one way.
Pic 10: Fit the 20mm tube to the top right pin on the brake cylinders and then attach the wiper motor to the frame and secure from behind with 1 x AP screw.
Pic 11: Fit the mount bracket 27A to the bottom of the frame and fix with 1 x AM screw.
Pic 12: Cut a 75mm length of tube and fit it to the pin on the top end of the frame.
Pic 13: Cut a 300mm length of tube and fit it to the pin on the top left of the brake cylinders.
Pic 14: Cut a 330mm length of tube and fit it to the pin on the top of the clutch cylinder.
Store the assembly safely for now.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 28A:
Steering rack and column.
Pic 1: Locate the steering column parts 28H, 28G and 2 x 28I.
They will assemble in the order shown.
Pic 2: Fit the parts together as shown and fix the end universal joint 28I shown on the left using 2 x SM screws.
The universal joint 28I between 28G and 28H is fixed with 4 x SM screws.
Pic 3: Fit the gear wheel on the steering rack into the location on the rack part 28B as shown.
Pic 4: Fit the clamp 28E over the gear and fix with 2 x AM screws.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 28B:
Pic 5: Retrieve the front frame assembly and fit the steering rack and column in place as shown.
The steering column goes under and between the clutch and brake pedal as indicated.
Fix the rack 28B in place using 3 x AM screws.
Pic 6: Another view of the steering column position.
Pic 7: Fix the top locating bracket 28F over the column using 2 x QM screws.
Pic 8: Fix the inner steering rack parts 28C and 2 x 28D together as shown and fix using 2 x AM screws.
Pic 9: Fit the assembled inner rack into the rack housing 28B with the geared end locating over the gear on the end of the steering column.
Pic 10: Fit the top rack cover 28A in place and fix using 4 x AM screws.
Store the assembly safely for now.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 29:
Central frame.
Pic 1: Push-fit the guard 29B onto the central frame 29A.
It will only fit one way.
Pic 2: Cut the tube 29C into two lengths – 80mm and 120mm.
Pic 3: Fit the two tubes onto the pins on the central frame as shown.
Pic 4: Retrieve the front frame assembled around 26A.
Fit the central frame 29A in place, at the centre of the 26A assembly as shown.
Pic 5: This shows a close up of how the parts fit together.
The two ‘U’ shaped sections on 29A should line up with the circular locations on 26A.
Pic 6: Holding the parts together, turn everything up the other way and fix the parts together with 1 x AM screw.
Pic 7: Shows a close up of the screw fixing.
NOTE – The assembly is only held together with one screw at present.
Store the assembly safely.roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 30:
Lower frame.
Pic 1: Push-fit the two horn parts 30B and 30C together as shown.
They will only fit one way.
Pic 2: Press-fit the horn assembly to the lower frame 30A as shown.
It will only fit one way.
Pic 3: Fit the central frame assembly from the previous stage in place as shown.
The fixing points for the upper frame 29A are highlighted.
Pic 4: The front fixing points for the frame are highlighted.
Pic 5: Turn the assembly over and fix the frames together using 5 x AM screws.
Store the assembly safely.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 31:
Front suspension.
Pic 1: Fit the two arm brackets 31C to the left lower arm 31B taking note that with the arm 31B upside down as shown, the small steps on the brackets 31C are at the top. This is important.
Fix with 2 x ABM screws from the outside.
Pic 2: Assemble the other suspension arm with parts 31A and 2 x 31C in the same way.
Pic 3: Assemble the two shock absorbers as shown using 2 x 31D and 2 x 31E.
Pic 4: Fit the shock absorbers to the suspension arms as shown with the adjuster knob facing inwards.
Fix using 1 x BM screw in each.
Pic 5: Retrieve the front frame assembly and place it upside down as shown.
Fit the left suspension arm 31B to the chassis locating the stepped brackets 31C in place.
Fix using 2 x TM screws.
Pic 6: Turn the frame around and fit the right suspension arm 31A to the chassis locating the stepped brackets 31C in place.
Fix using 2 x TM screws.
Store the assembly safely.
roymattblack attached the following image(s):
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,883 Points: 14,795 Location: ipswich
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STAGE 32:
Front left bulkhead.
Pic 1: Press-fit the air hose connector 32B to the bulkhead 32A as shown.
It will only fit one way.
Pic 2: Locate the two air hose parts 32C and 32D.
Pic 3: Press-fit the two parts together.
Pic 4: Fit the bulkhead 32A to the main frame as shown.
The steering arm indicated passes through the rectangular slot in the panel.
The steering arm will pass through easily if you turn the bulkhead panel sideways first, then straighten it when he arm is through.
Pic 5: The bulkhead panel fixes with 2 x M screws.
You will need a longer screwdriver to do this.
Pic 6: 2 x AM screws shown.
Pic 7: Store the assembly safely.
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