Pack 01

BUILD INSTRUCTIONS

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      Advice from the experts

      Spare screws are included with each part. Occasionally, you may be instructed to keep spare or unused screws for a later stage. Keep these spares in a safe place and label them correctly.

      Please make sure you don’t mix up the screws. They look quite similar, but the threads do vary slightly. Using the wrong screws may damage the parts. Only use the correct size screwdriver that fits the screw head firmly.

      When securing parts together using multiple screws, fit each screw loosely to ensure all the parts are correctly aligned before gently tightening them firmly, but not overtight, in the order in which you placed them.

      The screwdriver can be magnetized by stroking it with a magnet (fridge magnet, etc.) enabling it to hold the screws and make assembly easier.

      If a screw is tight going into a metal part, do not force it as you may shear the head off. Remove it and put a tiny smear of Vaseline, soap or light oil on the thread. That will lubricate it and make it easier to tighten.

      Some parts will require a little glue for assembly. Please apply glue sparingly and use a cocktail stick so that you don’t use too much nor apply the glue too heavily. We recommend superglue gel or Extra Thin Liquid modeling glue. Where possible, parts should be test-fitted in place before gluing.

      Make sure you have good ventilation when using adhesives and to replace caps firmly.

      Use a magnet to help find screws that have fallen on the floor.

      Use masking tape to hold parts temporarily in place.

      Cut parts from a sprue (framework) with side cutters or a craft knife. Side cutters tend to be easiest.

      During the course of this build, you will receive many pieces that you will assemble immediately – following the instructions in the corresponding stage – and other pieces that you should store safely to one side, for use in future assembly stages.

      Always protect the paint finish on components by placing a cutting mat, sheet of white paper or soft cloth on your work surface.

      When plugging in wires, ensure the power is switched off. Tweezers can be used to fit the PVC wires by gripping carefully around 5mm from the end of the wire. If a wire needs to be removed from a socket, do not pull on the wire as this could damage the connection. Grip the plug with tweezers to remove it.

      When you see this symbol, pay attention to the instruction text in bold and check the orientation of the parts in the image as this will be particularly important for assembly in later stages.

      WARNING: Some parts are assembled using magnets. These magnets can cause serious injury if they are swallowed. Keep away from children. If you suspect a magnet has been swallowed, seek medical help straight away.

      This is not a toy. Not suitable for children under 14 years old due to small parts. Adult supervision required.

      PACK 01 PARTS

      Stage 01: Building the helm station

      Step 1

      Start by taking the circuit tester (1-B) and attach the power cable (1-A). Attach the other end of the power cable to a power supply.

      Plug in wire 3-R and check the LED lights up.

      Next, plug in wire 3-S and check the LED lights up.

      Carefully remove the wires by pulling gently on the plug. Do not pull by the wire as this could damage the connection.

      a
      b

      Step 2

      Next, assemble your ORCA screwdriver by inserting part 1-C into part 1-F.

      a
      b

      Step 3

      You will now start building the helm station.

      Start by gluing part 1-E to part 1-D.

      a
      b

      Step 4

      Fit the assembly to part 1-J with two PWB-D4 screws.

      a
      b

      Step 5

      Glue the assembly to part 1-I, then attach part 1-N with one PWB-D6 screw.

      a
      b
      c

      Step 6

      Glue part 1-K to part 1-O.

      a
      b

      Step 7

      Fit the assembly to part 1-I with two PWB-D4 screws.

      a
      b

      Step 8

      Cut parts 1-L and 1-M from the sprue, then fit part 1-M into part 1-H. Make sure part 1-H is in the orientation shown.

      a
      b
      c

      Step 9

      Fit part 1-L into the opposite side of part 1-H.

      a
      b

      Step 10

      Glue the assembly to part 1-O.

      a
      b

      Step 11

      Glue part 1-G to part 1-O.

      a
      b

      Step 12

      Identify and prepare parts 4-A, 4-B and 4-C, as shown.

      a

      Step 13

      Bend one end of part 4-A.

      Take the assembly and check the distance between the holes, as shown (image b), then bend the other end of part 4-A to the correct length.

      a
      b
      c

      Step 14

      Insert the ends of part 4-A into the holes, then bend them over behind the panel to hold the part in place.

      a
      b
      c

      Step 15

      Bend one end of part 4-B, then fit it to the assembly, as shown.

      a
      b
      c

      Step 16

      Bend the other end of part 4-B, as shown, then press the ends behind the panel to hold the part in place.

      a
      b
      c

      Step 17

      Fit parts 4-C to the assembly using the same process.

      a
      b

      STAGE COMPLETE

      Stage 02: Assembling and fitting the searchlight

      Step 1

      Glue part 3-A to part 3-B.

      a
      b

      Step 2

      Glue part 3-E to the assembly. You may find it easier to fit part 3-E to the searchlight assembly (see steps 3–5) before gluing it in place.

      a
      b

      Step 3

      Peel the protective film from part 3-G and fit it into part 3-D.

      a
      b

      Step 4

      Cut part 3-C from the sprue, then fit part 3-C into part 3-D, as shown.

      a
      b
      c

      Step 5

      Fit part 3-Q to part 3-D.

      a
      b

      Step 6

      Thread part 3-Q through the assembly from step 2.

      a
      b

      Step 7

      Carefully bend the wires, then fit part 3-D to part 3-E, as shown.

      a
      b
      c

      Step 8

      Fit part 3-Q into part 3-H in the orientation shown, then test part 3-Q using the circuit tester.

      a
      b
      c

      STAGE COMPLETE

      Stage 03: Building the flying bridge side panels

      Step 1

      Identify parts 2-B (number 2), 2-G (number 4) and 2-E (number 2), as shown.

      a
      b

      Step 2

      Glue parts 2-G and 2-E to part 2-B, as shown.

      a
      b
      c

      Step 3

      Glue part 2-H (number 3) to part 2-B.

      a
      b
      c

      Step 4

      Take parts 3-R (letter R) and 3-F, then peel one part 3-F from the transparent film.

      a
      b

      Step 5

      Stick part 3-F to part 3-R, as shown, then peel off the backing paper from part 3-F.

      a
      b

      Step 6

      Stick part 3-R to part 2-B. Ensure the solder joints on part 3-R are positioned below the indicated line (red line) to avoid interference when fitting part 2-C later (Stage 04, Step 10).

      a
      b

      Step 7

      Identify part 2-D (number 1), parts 2-E (number 2) and 2-F (number 1). Glue parts 2-E and 2-F to part 2-D, as shown.

      a
      b
      c

      Step 8

      Glue part 2-H (number 3) to part 2-B.

      a
      b

      Step 9

      Stick the second part 3-F to 3-S (letter L), then peel off the backing paper from part 3-F.

      a
      b
      c

      Step 10

      Stick part 3-S to part 2-D. Ensure the solder joints on part 3-S are positioned below the indicated line (red line) to avoid interference when fitting part 2-A later (Stage 04, Step 8).

      a
      b

      Step 11

      Fit the assembly from stage 02 to part 2-N with three PWB-D4 screws.

      a
      b
      c

      Step 12

      Fit part 2-K to the assembly with one PWB-D4 screw.

      a
      b

      Step 13

      Take the wire from part 2-D and wrap a number 1 label from part 2-M around the wire, positioning the label 10 mm from the plug, as shown.

      a
      b
      c

      Step 14

      Take the wire from part 2-B and wrap a number 2 label from part 2-M around the wire, positioning the label 10 mm from the plug, as shown.

      a

      Step 15

      Fit part 2-D to the assembly with one PWB-D4 screw.

      a
      b

      Step 16

      Fit part 2-B to the assembly with one PWB-D4 screw.

      a
      b

      STAGE COMPLETE

      Stage 04: Building and fitting the navigation lights and other flying bridge components

      Step 1

      Fit the assembly from stage 03 to part 3-P, routing the number 1 and number 2 wires through the openings, as shown. Secure the parts together with six PWB-D4 screws.

      a
      b
      c

      Step 2

      Route the wires through the opening, as shown.

      a
      b

      Step 3

      Plug the wires into the corresponding sockets on the circuit board.

      a
      b

      Step 4

      Cut part 3-K (letter L) from the sprue. Trim any leftover plastic from the sprue, as shown (images b and c).

      a
      b
      c

      Step 5

      Cut part 3-I from the sprue, then glue part 3-I to part 3-K.

      a
      b
      c

      Step 6

      Glue the assembly to part 2-I.

      a
      b

      Step 7

      Glue the assembly to part 2-A.

      a
      b

      Step 8

      Glue part 2-A to the flying bridge assembly.

      a
      b

      Step 9

      Glue parts 3-J, 3-L and 2-J in the same way, then glue the assembly to part 2-C.

      a
      b
      c

      Step 10

      Glue part 2-C to the flying bridge assembly.

      a
      b

      Step 11

      Wrap the wire from part 3-Q with the number 3 from part 2-M.

      a
      b

      Step 12

      Glue the searchlight assembly to the flying bridge, as shown.

      a
      b

      Step 13

      Plug the number 3 wire into the corresponding socket on the circuit board, then press the wire into the retaining pins, as shown.

      a
      b

      Step 14

      Take parts 3-N and 3-M (letters L) and glue them together, as shown.

      a
      b
      c

      Step 15

      Glue the assembly to the flying bridge in the orientation shown.

      a
      b

      Step 16

      Glue part 3-O to the assembly.

      a
      b

      Step 17

      Take parts 3-N and 3-M (letters R) and glue them together, as shown.

      a
      b
      c

      Step 18

      Glue the assembly to the flying bridge in the orientation shown.

      a
      b

      Step 19

      Glue part 3-O to the assembly.

      a
      b

      Step 20

      Glue part 2-L to the assembly.

      a
      b

      Step 21

      Insert part 4-B through the hole in part 3-P.

      a

      Step 22

      Insert the end of part 4-B into the hole under the helm station (image a), then bend the other end to hold it in place (image c).

      a
      b
      c

      STAGE COMPLETE

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