Pack 10

BUILD INSTRUCTIONS

      If you'd prefer to download a PDF version of these instructions, choose to save as PDF from the print dialog.

      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 74: Fitting the bonnet hinge and rear gun mount

      STAGE 74 PARTS

      Step 1

      Turn the assembly over and fit part 74-A with 3 SM screws, as shown.

      a
      b

      Step 2

      Remove the rear seat, as shown. Keep the screws in a safe place.

      a
      b

      Step 3

      Fit part 74-B to part 74-C with 2 DM screws.

      a
      b

      Step 4

      Fit part 74-B to the cockpit assembly with 4 DM screws.

      a
      b

      Step 5

      Re-fit the rear seat in place.

      a
      b

      Step 6

      Building a jerry can

      Fit part 74-D to part 74-E with 2 DP screws.

      a
      b

      Step 7

      Fit parts 74-H to part 74-D.

      a
      b

      Step 8

      Fit part 74-F and part 74-G to complete the jerry can, as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 75: Fitting the horn and bonnet

      STAGE 75 PARTS

      Step 1

      Fit part 75-B to part 75-A with 1 CP screw.

      a
      b

      Step 2

      Fit part 75-B to the firewall with 2 DM screws.

      a
      b

      Step 3

      Fit one part 75-C to the bonnet assembly (stage 60) with 2 ADM screws.

      a
      b

      Step 4

      Fit the other part 75-C to the bonnet assembly with 2 ADM screws.

      a
      b

      Step 5

      Fit the bonnet assembly to part 73-A with 3 SM screws, as shown.

      a
      b

      Step 6

      Building a jerry can

      Fit part 75-D to part 75-E with 2 DP screws.

      a
      b

      Step 7

      Fit parts 75-H to part 75-D.

      a
      b

      Step 8

      Fit part 75-F and part 75-G to complete the jerry can, as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 76: Fitting the cockpit to the chassis

      STAGE 76 PARTS

      Step 1

      Fit part 76-B through part 76-A. Repeat this procedure to make a second assembly.

      a
      b
      c

      Step 2

      Fit one 76-A to the chassis assembly (stage 58) with 2 ADM screws, as shown.

      a
      b

      Step 3

      Fit part 76-C to part 76-B.

      a
      b

      Step 4

      Fit the other 76-A to the other side of the chassis assembly with 2 ADM screws.

      a
      b

      Step 5

      Fit the other part 76-C to part 76-B.

      a
      b

      Step 6

      Fit one jerry can (stages 27 and 28) on each side of the body, as shown.

      a
      b
      c

      Step 7

      Turn the assembly over and locate wire 71-A. Wire 71-A divides into two: a short LED wire (A) and a long LED wire (B).

      a

      Step 8

      Fit the two LEDs into the holes, as shown.

      a
      b

      Step 9

      Cut four a strips of tape (76-I).

      a

      Step 10

      Stick three strips of tape 76-I over the wires to hold them in place, as shown.

      a

      Step 11

      Remove part 71-C from the cockpit assembly. Keep part 71-C and the screw in a safe place.

      a

      Step 12

      Stick the remaining strip of tape 76-l over the wires, as shown.

      a

      Step 13

      Thread the LEDs from wire 71-B through the chassis (see step 16), then fit the cockpit assembly to the chassis. Connect the steering column at the same time, as indicated by the blue arrow.

      Ensure the bonnet latches do not get caught under the bonnet (image b).

      a
      b
      c

      Step 14

      Turn the assembly over and check the part indicated by the red arrow is fitted correctly. Ensure the wires are not caught under the screw holes.

      a
      b

      Step 15

      Screw the cockpit assembly and chassis assembly together with 6 PM screws and 2 LM screws, as shown.

      a

      Step 16

      Locate wire 71-B. Wire 71-B divides into two: a short LED wire (A) and a long LED wire (B).

      a

      Step 17

      Thread the short LED wire through the assembly, as shown.

      a

      Step 18

      Thread the long LED wire under the front differential.

      a
      b

      Step 19

      Route the wire between the two posts (circled). Re-fit part 71-C with 1 CP screw.

      a
      b

      Step 20

      Thread the long wire (B) through the assembly. Turn the assembly over and fit the LED into the left headlamp.

      a
      b
      c

      Step 21

      Route the short wire (A) underneath the voltage regulator and battery. Fit the LED into the right headlamp.

      a
      b
      c

      Step 22

      Press the air cleaner firmly in place, as shown.

      a
      b

      Step 23

      Fit part 7-C to the air cleaner, as shown.

      a
      b

      Step 24

      Fasten the steering column with 1 FM screw.

      a

      Step 25

      Building a jerry can

      Fit part 76-D to part 76-E with 2 DP screws.

      a
      b

      Step 26

      Fit parts 76-H to part 76-D.

      a
      b

      Step 27

      Fit part 76-F and part 76-G to complete the jerry can, as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 77: Fitting the left grab handles

      STAGE 77 PARTS

      Step 1

      Fit part 77-A to the left side of the jeep with 2 DM screws.

      a
      b

      Step 2

      Fit part 77-B to the jeep with 2 DM screws.

      a
      b

      Step 3

      Building a jerry can

      Fit part 77-C to part 77-D with 2 DP screws.

      a
      b

      Step 4

      Fit parts 77-G to part 77-C.

      a
      b

      Step 5

      Fit part 77-E and part 77-F to complete the jerry can, as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 78: Fitting the right grab handles

      STAGE 78 PARTS

      Step 1

      Fit part 78-A to the right side of the jeep with 2 DM screws.

      a
      b

      Step 2

      Fit part 78-B to the jeep with 2 DM screws.

      a
      b

      Step 3

      Building a jerry can

      Fit part 78-C to part 78-D with 2 DP screws.

      a
      b

      Step 4

      Fit parts 78-G to part 78-C.

      a
      b

      Step 5

      Fit part 78-E and part 78-F to complete the jerry can, as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 79: Fitting the rear reflectors and assembling a Vickers K machine gun (1)

      STAGE 79 PARTS

      Step 1

      Identify the recesses on parts 79-B and 79-C, as circled in the image.

      a

      Step 2

      Fit part 79-B to the left side of the jeep with 1 VM screw. Ensure the part is in the orientation shown.

      a
      b

      Step 3

      Fit the pin on part 79-A into the recess in part 79-B.

      a
      b

      Step 4

      Fit part 79-C to the rear of the jeep with 1 VM screw. Ensure the part is in the orientation shown.

      a
      b

      Step 5

      Fit part 79-A to part 79-C.

      a
      b

      Step 6

      Fit part 79-I to part 79-D with 1 DM screw.

      a
      b

      Step 7

      Fit part 79-E to part 79-D.

      a
      b

      Step 8

      Fit part 79-H to part 79-G with 1 MP screw.

      a
      b

      Step 9

      Fit part 79-F to part 79-H with 2 RP screws.

      Position part 79-F as shown in image c.

      a
      b
      c

      Step 10

      Fit part 79-F to part 79-D.

      a
      b

      Step 11

      Fit part 79-G to part 79-D, as shown.

      a
      b

      STAGE COMPLETE

      Stage 80: Fitting the rear reflectors and assembling a Vickers K machine gun (2)

      STAGE 80 PARTS

      Step 1

      Identify the recesses on parts 80-B and 80-C, as circled in the image.

      a

      Step 2

      Fit part 80-B to the right side of the jeep with 1 VM screw.

      a
      b

      Step 3

      Fit the pin on part 80-A into the recess in part 80-B.

      a
      b

      Step 4

      Fit part 80-C to the rear of the jeep with 1 VM screw.

      a
      b

      Step 5

      Fit part 80-A to part 80-C.

      a
      b

      Step 6

      Fit part 80-E to part 80-D.

      a
      b

      Step 7

      Fit part 80-J to part 80-D.

      a
      b

      Step 8

      Fit part 80-I to part 79-D (stage 79).

      a
      b

      Step 9

      Fit part 80-H to the assembly.

      a
      b

      Step 10

      Fit part 80-D to part 79-D with 2 SM screws.

      a
      b

      Step 11

      Fit part 80-G into the assembly.

      a
      b

      Step 12

      Fit part 80-F into the assembly.

      a
      b

      STAGE COMPLETE

      Stage 81: Fitting the tail lamps and assembling a Vickers K machine gun (1)

      STAGE 81 PARTS

      Step 1

      Fit part 81-B to part 81-A.

      a
      b

      Step 2

      Fit part 81-A to the rear-left side of the jeep.

      a
      b

      Step 3

      Fit part 81-H to part 81-C with 1 DM screw.

      a
      b

      Step 4

      Fit part 81-D to part 81-C.

      a
      b

      Step 5

      Fit part 81-G to part 81-F with 1 MP screw.

      a
      b

      Step 6

      Fit part 81-E to part 81-G with 2 RP screws.

      Position part 81-E as shown in image c.

      a
      b
      c

      Step 7

      Fit part 81-E to part 81-C.

      a
      b

      Step 8

      Fit part 81-F to part 81-C, as shown.

      a
      b

      STAGE COMPLETE

      Stage 82: Fitting the tail lamps and assembling a Vickers K machine gun (2)

      STAGE 82 PARTS

      Step 1

      Fit part 82-B to part 82-A.

      a
      b

      Step 2

      Fit part 82-A to the rear-right side of the jeep.

      a
      b

      Step 3

      Fit part 82-D to part 82-C.

      a
      b

      Step 4

      Fit part 82-I to part 82-C.

      a

      Step 5

      Fit part 82-H to part 81-C (stage 81).

      a
      b

      Step 6

      Fit part 82-G to the assembly.

      a
      b

      Step 7

      Fit part 82-C to part 81-C with 2 SM screws.

      a
      b

      Step 8

      Fit part 82-F into the assembly.

      a
      b

      Step 9

      Fit part 82-E into the assembly.

      a
      b

      STAGE COMPLETE

      Stage 83: Fitting the water condenser and footman loops

      STAGE 83 PARTS

      This stage contains both black and painted yellow SM screws. These have been labelled SM (B) for black and SM (Y) for yellow in the instructions.

      Step 1

      Fit part 83-C to part 83-B. Fit the pin into the recess, as indicated by the red circles.

      a
      b

      Step 2

      Fit part 83-F to part 83-B with 2 CP screws.

      a
      b

      Step 3

      Fit part 83-E to part 33-D, as shown.

      a
      b

      Step 4

      Feed part 83-E behind the radiator and through the circled opening.

      a
      b

      Step 5

      Fit part 83-D to part 83-E.

      a
      b

      Step 6

      Fit part 83-F to part 2-A with 2 SM (B) screws.

      a
      b

      Step 7

      Fit part 83-D into part 83-C.

      a
      b

      Step 8

      Fit one part 83-A to the rear of the jeep with 2 SM (Y) screws.

      a
      b

      Step 9

      Fit the two remaining parts 83-A with 4 SM (Y) screws, as shown.

      a

      STAGE COMPLETE

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