Pack 04

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 04 PARTS

      Stage 14: Fitting the windows

      Step 1

      Peel the protective film from both sides of part 10-D, then glue part 10-D to part 10-C.

      a
      b
      c

      Step 2

      Glue part 10-B to the assembly.

      Repeat steps 1 and 2 to build two windows.

      a
      b
      c

      Step 3

      Fit the windows to part 10-A.

      a
      b

      Step 4

      Glue part 12-D to the assembly.

      a
      b

      Step 5

      Remove the flying bridge from the galley. Glue the assembly in place.

      Secure the parts using three PWB 2.3x6 screws.

      Use masking tape to hold the assembly in place while the glue dries.

      a
      b
      c

      Step 6

      The windows can be opened, as shown.

      a

      STAGE COMPLETE

      Stage 15: Building the mast (1)

      Step 1

      Take wire 13-G and wire 13-H. Wire 13-G has one LED and wire 13-H has two LEDs, as indicated by the circles.

      Plug the wires into the circuit tester (1-B) to test the LEDs, as shown in images b and c.

      Ensure extra care is taken when handling the LEDs and that the LEDs are tested after fitting them in each stage.

      a
      b
      c

      Step 2

      Wrap a number 9 label from part 12-A around wire 13-G (one LED), and position the label 10 mm from the plug.

      a
      b
      c

      Step 3

      Wrap a number 10 label from part 12-A around wire 13-H (two LEDs), positioning the label 10 mm from the plug.

      a
      b

      Step 4

      Note that the parts for the mast are numbered 1–6, as shown.

      a

      Step 5

      Thread the LEDs from wires 13-G and 13-H through part 13-A (number 1).

      a
      b
      c

      Step 6

      Thread the LEDs through part 13-B (number 2), then glue part 13-B to part 13-A.

      a
      b
      c

      Step 7

      Cut parts 13-P and 13-Q from the sprue. Position the LED from wire 13-G into part 13-Q then glue part 13-P into place, as shown.

      a
      b
      c

      Step 8

      Cut part 13-S from the sprue. Glue part 13-S to the assembly.

      a
      b
      c

      Step 9

      Glue part 13-Q to part 13-B.

      a
      b

      Step 10

      Thread the LEDs from wire 13-H through part 13-C (number 3), then glue part 13-C to part 13-B.

      a
      b
      c

      Step 11

      Thread the LEDs from wire 13-H through part 12-E, then glue part 12-E to part 13-C.

      a
      b

      STAGE COMPLETE

      Stage 16: Building the mast (2)

      Step 1

      Thread the LEDs from wire 13-H through part 13-D (number 4), then glue part 13-D to part 13-C.

      a
      b
      c

      Step 2

      Take part 12-I and identify the two notches (circled). Glue part 12-I to part 13-D in the orientation shown.

      a
      b
      c

      Step 3

      Position wire 13-H in the slot on part 13-D (circled).

      a

      Step 4

      Thread the LED through the assembly and position the wire in the notch, as shown.

      a
      b
      c

      Step 5

      Repeat steps 3 and 4 for the other wire, and route the wire to the opposite side.

      a

      Step 6

      Peel one part 12-C from the backing paper.

      a

      Step 7

      Stick part 12-C to one LED on wire 13-H then wrap part 12-C around the wire, as shown.

      a
      b
      c

      Step 8

      Fit part 12-C into part 12-F.

      a
      b

      Step 9

      Cut one part 13-M from the sprue. Identify the ridge on part 13-M (circled).

      a
      b

      Step 10

      Position the wires in the notch (circled) on part 12-F, then glue part 13-M to part 12-F. Fit the ridge into the notch.

      a
      b
      c

      Step 11

      Fit part 13-M to part 12-I. DO NOT GLUE.

      a
      b

      Step 12

      Glue part 12-G to part 12-I.

      a
      b

      Step 13

      Repeat steps 6–12 on the opposite side.

      a

      Step 14

      Carefully pull the excess wire back through the mast.

      a
      b
      c

      Step 15

      Cut parts 13-R from the sprue.

      a

      Step 16

      Glue parts 13-R to parts 12-F.

      a
      b
      c

      STAGE COMPLETE

      Stage 17: Building the mast (3)

      Step 1

      Glue part 14-E to the mast assembly.

      a
      b

      Step 2

      Glue part 12-H to the mast assembly.

      a
      b

      Step 3

      Glue part 13-E (number 5) to the mast assembly.

      a
      b

      Step 4

      Glue part 12-J to the mast assembly.

      a
      b

      Step 5

      Glue part 13-F (number 6) to the mast assembly.

      a
      b

      Step 6

      Cut parts 13-L (number 1) from the sprue. Glue one part 13-L to the mast assembly, as shown.

      a
      b
      c

      Step 7

      Glue the second part 13-L to the opposite side of the assembly.

      a
      b

      Step 8

      Cut parts 13-K (number 2) from the sprue. Glue one part 13-K to the mast assembly, as shown.

      a
      b
      c

      Step 9

      Glue the second part 13-K to the opposite side of the assembly.

      a
      b

      Step 10

      Cut part 13-J (number 4) from the sprue. Glue part 13-J to the mast assembly, as shown.

      a
      b
      c

      Step 11

      Cut parts 13-O (number 3) from the sprue. Glue one part 13-O to the other side of the assembly, opposite part 13-J.

      a
      b

      Step 12

      Glue the remaining parts 13-O to the mast assembly, as shown.

      a

      Step 13

      Cut fourteen parts 13-N from the sprue.

      a

      Step 14

      Identify the square-shaped holes in the mast for fitting parts 13-N.

      Glue one part 13-N to the mast assembly.

      a
      b
      c

      Step 15

      Continue to glue parts 13-N to the mast assembly, as shown.

      a
      b

      Step 16

      Cut fourteen parts 13-I from the sprue. Glue one part 13-I into the hole opposite part 13-N, as shown.

      a
      b
      c

      Step 17

      Continue to glue parts 13-I to the mast assembly.

      a

      STAGE COMPLETE

      Stage 18: Assembling galley accessories

      Step 1

      Assembling the books

      Prepare parts 11-A to 11-H, which are numbered 1–8, as shown.

      a

      Step 2

      Read through steps 2–6 and test-fit the parts before gluing. Parts 11-A, 11-B, and 11-C are shown with the numbers facing you.

      Glue part 11-B (number 2) to part 11-A (number 1), then glue part 11-C (number 3) to the assembly.

      a
      b
      c

      Step 3

      Parts 11-E, 11-F, 11-G and 11-H are shown with the numbers facing away from you.

      Glue part 11-E (number 5) to part 11-D (number 4), then glue part 11-F (number 6) to the assembly.

      a
      b
      c

      Step 4

      Glue part 11-G (number 7) to the assembly.

      a
      b

      Step 5

      Glue part 11-H (number 8) to the assembly.

      a
      b

      Step 6

      Glue the two assemblies together, as shown.

      a
      b

      Step 7

      Assembling a toolbox

      Glue part 11-I to part 11-J.

      a
      b

      Step 8

      Assembling a first aid kit

      Cut part 13-U from the sprue, then glue part 13-U to part 11-L.

      a
      b
      c

      Step 9

      Glue part 11-K to part 11-L.

      a
      b

      Step 10

      Assembling a thermos flask

      Cut part 13-T from the sprue.

      a

      Step 11

      Glue part 13-T to part 14-B, then glue part 14-B to part 14-C.

      a
      b
      c

      Step 12

      Assembling a binoculars case

      Cut parts 14-F from the sprue.

      a

      Step 13

      Fit part 12-B to parts 14-F, as shown.

      a
      b
      c

      Step 14

      Glue parts 14-F to part 14-D.

      a
      b
      c

      Step 15

      Keep part 14-A and the other accessories in a safe place.

      a

      STAGE COMPLETE

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