Pack 01

BUILD INSTRUCTIONS

      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 01: Building the radiator grille

      STAGE 01 PARTS

      Step 1

      Fit part 1-B to part 1-C, then repeat to make two.

      a
      b

      Step 2

      Parts 1-D and 1-E are marked with L (left) and R (right).

      a

      Step 3

      Attach part 1-C to part 1-D with 1 AP screw.

      a
      b

      Step 4

      Attach the other part 1-C to part 1-E with 1 AP screw.

      a
      b

      Step 5

      Fit part 1-D to part 1-A with 1 DM screw.

      a
      b

      Step 6

      Fit part 1-E to part 1-A with 1 DM screw.

      a

      Step 7

      Fit part 1-H to part 1-G, then repeat to make two.

      a
      b

      Step 8

      Fit part 1-G to part 1-F, then repeat to make two.

      a
      b

      Step 9

      Fit part 1-F to part 1-I with 1 AP screw.

      a
      b

      Step 10

      Fit part 1-I to part 1-A with 1 DM screw.

      a
      b

      Step 11

      Fit part 1-F to part 1-J with 1 AP screw.

      Fit part 1-J to part 1-A with 1 DM screw.

      a
      b

      Step 12

      Fit part 1-K to part 1-A with 1 DM screw.

      a
      b

      STAGE COMPLETE

      Stage 02: Building the bonnet

      STAGE 02 PARTS

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

      Step 1

      Fit part 2-C through part 2-B, then repeat to make two.

      a
      b
      c

      Step 2

      Fit part 2-B to part 2-A with 2 ADM screws.

      Tip: Use oil on painted screws to tighten them.

      a
      b

      Step 3

      Fit part 2-B to the other side of part 2-A with 2 ADM screws.

      a

      Step 4

      Fit part 2-D to part 2-A with 2 ADM screws.

      a
      b

      Step 5

      Fit part 2-D to the other side of part 2-A with 2 ADM screws.

      a

      Step 6

      Fit part 2-E to part 2-C.

      Hook part 2-E into part 2-D.

      a
      b

      Step 7

      Fit part 2-E to part 2-C on the other side of part 2-A in the same way.

      a

      STAGE COMPLETE

      Stage 03: Building a wheel (1)

      STAGE 03 PARTS

      Step 1

      Place part 3-A in a bowl of hot water to soften it.

      After 1–2 minutes, remove part 3-A with tweezers then dry with a cloth.

      a

      Step 2

      Fit part 3-B to part 3-A.

      a
      b

      Step 3

      Fit part 3-C to part 3-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

      Fit part 3-F to part 3-C with 2 CM screws.

      a
      b

      Step 6

      You can place part 3-E inside the assembly to keep it safe. It will be needed at a later stage.

      a

      Step 7

      Fit part 3-D to part 3-B.

      a
      b

      STAGE COMPLETE

      Stage 04: Building the engine (1)

      STAGE 04 PARTS

      Step 1

      Fit part 4-F to part 4-C with 2 CP screws.

      a
      b

      Step 2

      This is assembly A.

      a

      Step 3

      Fit part 4-E to part 4-B with 3 DM screws.

      a
      b

      Step 4

      Fit part 4-D to part 4-B with 2 CP screws.

      a
      b

      Step 5

      This is assembly B.

      a

      Step 6

      Fit assembly A to assembly B.

      a
      b

      Step 7

      Fix assembly A to assembly B with 2 FM screws.

      a

      Step 8

      Fit 4-A to assembly C with 2 FM screws.

      a
      b

      STAGE COMPLETE

      Stage 05: Building the engine (2)

      STAGE 05 PARTS

      Step 1

      Cut parts 5-E from the sprue.

      a

      Step 2

      Fit part 5-E to part 5-D.

      a
      b

      Step 3

      Fit part 5-E to part 5-F.

      a
      b

      Step 4

      Fit four more parts 5-E as shown.

      a

      Step 5

      Fit part 5-D to assembly C (stage 04) with 2 DM screws.

      a
      b

      Step 6

      Fit part 5-F to the assembly.

      a
      b

      Step 7

      Cut parts 5-B from the sprue.

      a

      Step 8

      Fit part 5-B to part 5-A.

      a
      b

      Step 9

      Fit three more parts 5-B as shown.

      a

      Step 10

      Fit part 5-C with 2 EM screws.

      a
      b

      Step 11

      Fit part 5-A to assembly C.

      a
      b

      Step 12

      Fix part 5-A with 1 CM screw.

      a

      Step 13

      Use a ruler to measure part 5-G and cut four 7cm pieces (5-G1) and one 4.5cm piece (5-G2).

      a
      b

      Step 14

      Fit part 5-G2 to assembly C.

      a
      b

      Step 15

      The image shows the sequence in which parts 5-G1 will be fitted.

      a

      Step 16

      Fit part 5-G1 to the first pin and thread it through the hole, then fit the other end of part 5-G1 as shown.

      a
      b

      Step 17

      Fit part 5-G1 to the second pin and thread it through the hole, then fit the other end of part 5-G1 as shown.

      a
      b

      Step 18

      Fit part 5-G1 to the third pin and thread it through the hole, then fit the other end of part 5-G1 as shown.

      a
      b

      Step 19

      Fit part 5-G1 to the fourth pin and thread it through the hole, then fit the other end of part 5-G1 as shown.

      a
      b

      STAGE COMPLETE

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