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.

      If the paint on the painted screws is scratched during the build, you can repaint it with Sand yellow (RAL 1002).

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

      Left and Right! When building your SAS Willys Jeep, the left- or right-hand side refers to that side as if you are sitting in the car.

      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.

      Stage 23: Fitting the rear brake plates

      STAGE 23 PARTS

      Step 1

      Fit part 23-A to part 21-B.

      a
      b

      Step 2

      Fit the other parts 23-A in place as shown.

      a
      b

      Step 3

      Fit part 23-B to part 21-A.

      a
      b

      Step 4

      Fit the second part 23-B to the other side as shown.

      a
      b

      STAGE COMPLETE

      Stage 24: Building the rear differential

      STAGE 24 PARTS

      Step 1

      Cut part 24-E from the sprue.

      a

      Step 2

      Fit part 24-E to part 24-C.

      a
      b

      Step 3

      Cut part 24-D from the sprue.

      a

      Step 4

      Fit part 24-D to part 24-A.

      a
      b

      Step 5

      Fit part 24-A to part 21-A with 2 FM screws.

      a
      b

      Step 6

      Fit part 24-F into parts 11-H and 24-A.

      a
      b

      Step 7

      Fit part 24-C to part 21-A.

      a
      b

      Step 8

      Fit part 24-B to part 24-A with 2 FM screws.

      a
      b

      STAGE COMPLETE

      Stage 25: Building the front right wheel (1)

      STAGE 25 PARTS

      Step 1

      Fit part 25-E to part 25-B with 2 CM screws.

      a
      b

      STAGE COMPLETE

      Stage 26: Building the front right wheel (2)

      STAGE 26 PARTS

      Step 1

      Place part 26-A in a bowl of hot water to soften it.

      After 1–2 minutes, remove part 26-A with tweezers, then dry with a cloth.

      a

      Step 2

      Fit part 25-A to part 26-A.

      a
      b

      Step 3

      Fit part 25-B to part 25-A. Make sure the screw holes are aligned (circled).

      a

      Step 4

      Squeeze the parts together and fix with 4 BM screws.

      a
      b

      Step 5

      You can place part 25-D inside the assembly to keep it safe. It will be needed at a later stage.

      a

      Step 6

      Fit part 25-C to part 25-A.

      a
      b

      STAGE COMPLETE

      Stage 27: Fitting the front brake hoses

      STAGE 27 PARTS

      Step 1

      Take part 27-E and cut two pieces to 10 cm (27-E1), cut one piece to 5 cm (27-E2), and cut another piece to 18 cm (27-E3).

      a
      b

      Step 2

      Fit part 27-D to part 27-C with 2 CP screws.

      a
      b

      Step 3

      Fit part 27-E1 to part 27-C.

      Tip: You can widen the end of the hose using a toothpick if needed.

      a
      b

      Step 4

      Fit part 27-E3 to part 27-C.

      a
      b

      Step 5

      Fit part 27-D to part 9-A with 2 DM screws.

      a
      b

      Step 6

      Fit part 27-E3 through the hole in part 9-A as shown. The dashed line shows part 27-E3 beneath the assembly.

      a
      b

      Step 7

      Fit parts 27-E1 and 27-E2 onto each side of part 27-B, as shown.

      a
      b
      c

      Step 8

      Fit part 27-E2 to a part 27-A and part 27-E1 to another part 27-A.

      a
      b

      Step 9

      Fit part 27-B to part 14-A. Note that part 27-E2 must be on the left-hand side and part 27-E1 must be on the right-hand side as shown.

      a
      b

      Step 10

      Fit part 27-A to part 18-A on the left-hand side.

      a
      b

      Step 11

      Fit part 27-A to part 18-A on the right-hand side.

      a
      b

      Step 12

      Fit part 27-E1 to part 27-B.

      a
      b

      Step 13

      Building a jerry can

      Fit part 27-F to part 27-G with 2 DP screws.

      a
      b

      Step 14

      Fit parts 27-J to part 27-F.

      a
      b

      Step 15

      Fit part 27-H and part 27-I to complete the jerry can as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 28: Fitting the rear brake hoses

      STAGE 28 PARTS

      Step 1

      Take part 28-D and cut two pieces to 7 cm (28-D1), and another piece to 5 cm (28-D2).

      a
      b

      Step 2

      Fit part 28-D2 to part 28-C.

      a
      b

      Step 3

      Fit part 27-E3 to part 28-C.

      a
      b

      Step 4

      Fit part 28-C to part 9-A.

      a
      b

      Step 5

      Fit parts 28-D1 to part 28-B.

      a
      b
      c

      Step 6

      Fit one part 28-D1 to one part 28-A, and fit the other part 28-D1 to the other part 28-A.

      a
      b

      Step 7

      Fit part 28-B to part 24-B.

      a
      b

      Step 8

      Fit part 28-A to part 23-B on the right-hand side.

      a
      b

      Step 9

      Fit part 28-A to part 23-B on the left-hand side.

      a
      b

      Step 10

      Fit part 28-D2 to part 28-B.

      a
      b

      Step 11

      Building a jerry can

      Fit part 28-E to part 28-F with 2 DP screws.

      a
      b

      Step 12

      Fit parts 28-I to part 28-E.

      a
      b

      Step 13

      Fit part 28-G and part 28-H to complete the jerry can as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 29: Fitting the exhaust pipe

      STAGE 29 PARTS

      Step 1

      Fit part 29-C to part 29-B with a CP screw.

      a
      b

      Step 2

      Fit part 29-A to part 29-B with a CP screw.

      a
      b

      Step 3

      Fit the assembly to part 9-A with a CP screw and a DM screw as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 30: Fitting the front left wheel

      STAGE 30 PARTS

      Step 1

      Fit part 30-A to part 9-A with 2 FM screws.

      a
      b
      c

      Step 2

      Fit part 30-B to part 30-A and part 9-A with 2 DM screws.

      a
      b

      Step 3

      Fit part 30-C to part 30-A with 4 DM screws.

      a
      b

      Step 4

      Take the wheel assembled in stage 3. Carefully remove part 3-D and retrieve part 3-E.

      a
      b

      Step 5

      Fit the wheel to part 18-A, then insert part 3-E as shown. Fit the parts together with an OM screw.

      a
      b
      c

      Step 6

      Fit part 3-D to the wheel.

      a
      b

      STAGE COMPLETE

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