Pack 05

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 wires in, 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.

      Left and Right! When building your For Your Eyes Only Citroën 2CV, 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 38: The oil cooler and the brake disc cooling air ducts

      STAGE 38 PARTS

      There is no assembly in Stage 38. The oil cooler and brake disc cooling air ducts will be attached to the engine in the next stage.

      STAGE COMPLETE

      Stage 39: Attaching the exhaust manifold

      STAGE 39 PARTS

      Step 1

      Attach part 39-A to part 39-D using one HP screw.

      a
      b

      Step 2

      Attach part 39-C to the assembly using one CP screw.

      a
      b

      Step 3

      Attach part 39-B to the assembly using one JP screw.

      a
      b
      c

      Step 4

      Take the assembly from stage 35 and position it on the engine assembly from stage 03, as shown.

      a
      b

      Step 5

      Position the exhaust manifold assembly from the previous stage on the engine assembly and connect the pipes, as shown.

      a
      b
      c

      Step 6

      Position the assembly from stage 36 onto the engine assembly, connect the pipes, and secure the parts together using one CP screw.

      a
      b
      c

      Step 7

      Insert the pins on part 36-E into the corresponding holes in the right cylinder cowling.

      a
      b

      Step 8

      Locate the cable from the right cylinder cowling. Glue the cable into the indicated hole in part 39-D.

      a
      b
      c

      Step 9

      Locate the outer cable from the left cylinder cowling. Glue the cable into the indicated hole in part 39-D.

      a
      b
      c

      Step 10

      Locate the indicated hole in the rear of the engine assembly. Glue the hose from part 39-D into the hole, as shown.

      a
      b

      Step 11

      Insert the pipe from part 37-A into the air duct, then attach part 37-A to the engine assembly using one SM screw.

      a
      b

      Step 12

      Insert the pipe from part 37-B into the air duct and push the two halves of the front silencer together. Attach part 37-B to the engine assembly using one SM screw.

      a
      b

      Step 13

      Glue the cable from part 3-I into the hole in part 37-B.

      a
      b
      c

      Step 14

      Attach part 38-A to the engine assembly using one RM screw.

      a
      b
      c

      Step 15

      Attach part 38-B to the engine assembly using one SM screw.

      a
      b
      c

      STAGE COMPLETE

      Stage 40: Attaching the air filter

      STAGE 40 PARTS

      Step 1

      Attach part 40-B to part 40-A using two CP screws.

      a
      b

      Step 2

      Attach part 40-C to the assembly using two CP screws.

      a
      b

      Step 3

      Insert part 40-D into the assembly.

      a
      b

      Step 4

      Position the air filter on the engine, as shown. Connect the pipes to the air filter, as shown in image c.

      a
      b
      c

      Step 5

      Secure the air filter using two SM screws.

      a

      STAGE COMPLETE

      Stage 41: Building the engine fan mount

      STAGE 41 PARTS

      Step 1

      Position part 41-C on part 41-A.

      a
      b

      Step 2

      Attach part 41-B to the assembly using one CP screw.

      a
      b

      STAGE COMPLETE

      Stage 42: Attaching the engine fan

      STAGE 42 PARTS

      Step 1

      Place part 42-C into part 42-A.

      a
      b

      Step 2

      Attach the engine fan mount to part 42-A using four JP screws.

      a
      b

      Step 3

      Attach the engine fan to the engine assembly using two CP screws and one SM screw.

      a
      b
      c

      Step 4

      Attach part 42-B to the engine fan, as shown.

      a
      b

      STAGE COMPLETE

      Stage 43: Attaching the steering track rod

      STAGE 43 PARTS

      Step 1

      Insert part 43-A into the steering arms. Then, turn the chassis over and secure part 43-A using two KM screws.

      a
      b
      c

      STAGE COMPLETE

      Stage 44: Fixing the engine to the chassis

      STAGE 44 PARTS

      Step 1

      Hook spring 44-G onto the engine fan, then attach the spring to the engine assembly, as shown.

      a
      b

      Step 2

      Insert one part 44-A through one part 44-B to make a drive shaft. Repeat with the remaining parts 44-A and 44-B to make a second drive shaft.

      a
      b
      c

      Step 3

      Insert the drive shafts, as shown.

      a
      b
      c

      Step 4

      Position the engine assembly on the chassis.

      a
      b

      Step 5

      Connect each drive shaft to the corresponding wheel hub.

      a
      b
      c

      Step 6

      Secure the engine to the chassis using two BM screws.

      a

      Step 7

      Attach part 44-E to the engine.

      a
      b

      Step 8

      Attach part 44-F to part 44-E.

      a
      b

      Step 9

      Locate the cable from the left brake disc (part 3-D). Glue the cable into the left-hand hole in part 44-C, as shown.

      a
      b
      c

      Step 10

      Locate the cable from the right brake disc (part 3-F). Route the cable to the left-hand side of the assembly, then glue the cable into the right-hand hole in part 44-C.

      a
      b
      c

      Step 11

      Push part 44-C into the chassis.

      a
      b

      Step 12

      Attach part 44-D to part 44-C.

      a
      b

      STAGE COMPLETE

      Stage 45: The front left mudguard

      STAGE 45 PARTS

      There is no assembly in Stage 45. The front left mudguard will be attached to the chassis in the next stage.

      STAGE COMPLETE

      Stage 46: Fitting the front left mudguard

      STAGE 46 PARTS

      Step 1

      Attach part 46-A to part 45-A using two KP screws.

      a
      b
      c

      Step 2

      Attach part 45-A to the chassis using two CP screws.

      a
      b
      c

      STAGE COMPLETE

      Stage 47: Fitting the front right mudguard and the ventilation hoses

      STAGE 47 PARTS

      Step 1

      Attach part 46-B to part 47-A using two KP screws.

      a
      b
      c

      Step 2

      Attach part 47-A to the chassis using two CP screws.

      a
      b
      c

      Step 3

      Identify part 46-C and part 46-D using the image. Position both parts as shown, paying particular attention to the angles indicated by the dashed red lines.

      a

      Step 4

      Push part 46-D through the front right mudguard and into the air duct.

      a
      b

      Step 5

      Push part 46-C through the front left mudguard and into the air duct.

      a

      STAGE COMPLETE

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