Pack 02
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 06 PARTS
Step 1
Fit part 6-J to part 6-I.
Step 2
Fit part 6-I to part 6-G with 1 AP screw.
Step 3
Fit part 6-H to part 6-G.
Step 4
Fit part 6-G to assembly A (stage 05) with 2 AP screws.
Step 5
Fit part 6-D to part 6-E with 1 AP screw.
Step 6
Fit part 6-D to assembly A with 1 DM screw.
Step 7
Fit part 6-C to assembly A with 1 DM screw.
Step 8
Fit part 6-B to part 6-A with 1 AP screw.
Step 9
Fit 6-A to assembly A.
Step 10
Fix with 2 DM screws.
Step 11
Take part 6-F and cut one piece to 7.5 cm (6-F1) , and cut another piece to 5 cm (6-F2).
Step 12
Fit 6-F1 to assembly A.
Step 13
Fit 6-F2 to assembly A.
STAGE COMPLETE
STAGE 07 PARTS
Step 1
Take part 7-C and cut one piece to 9 cm (7-C1), and cut another piece to 2.5 cm (7-C2).
Step 2
Fit part 7-B to part 7-A.
Step 3
Fit part 7-C2 to part 7-A.
Step 4
Fit part 7-A to assembly A (stage 06) with 1 DM screw.
Step 5
Fit part 7-J into part 7-I.
Step 6
Fit part 7-K to part 7-J with 1 BP screw.
Step 7
Fit part 7-I to assembly A with 1 DM screw.
Step 8
Fit part 7-G into part 7-F.
Step 9
Fit part 7-H to part 7-F. You may find it easier to fit the part while still on the sprue.
Cut the sprue off from part 7-H as shown, taking care not to lose the spare 7-H still attached to the sprue.
Step 10
Fit part 7-E to part 7-F with 1 BP screw.
Step 11
Fit part 7-C1 to part 7-H.
Step 12
Fit part 7-D to part 7-E.
Attach part 7-D to assembly A with 3 AM screws.
Step 13
Thread 7-C1 through the hole in part 7-D.
Step 14
Fit part 7-C1 to assembly A as shown.
STAGE COMPLETE
STAGE 08 PARTS
Step 1
Fit part 8-C to part 8-B.
Step 2
Fit part 8-B to part 8-A with 1 DM screw.
Step 3
Fit part 8-D to assembly A (stage 07) with 1 DM screw.
Step 4
Fit part 8-F to part 8-E.
Step 5
Fit part 8-E to assembly A.
Step 6
Fit part 8-G to assembly A with 1 DP screw.
Step 7
Fit part 8-I to part 4-E.
Step 8
Fit part 8-A (step 2) to assembly A with 1 DM screw.
Step 9
Fit part 8-H to the assembly as indicated by the dashed red line.
STAGE COMPLETE
STAGE 09 PARTS
There is no assembly in this stage.
STAGE COMPLETE
STAGE 10 PARTS
Step 1
Fit parts 10-A to part 9-A (stage 09) in the orientation shown with 4 DM screws.
Keep parts 10-B in a safe place, they will be needed in a later stage.
STAGE COMPLETE
STAGE 11 PARTS
Step 1
Fit part 11-A to part 9-A (stage 09) with 2 CP screws.
Step 2
Fit part 11-B to part 9-A with 1 FM screw.
Make sure to fit the part in the orientation shown by the red line.
Step 3
Fit parts 11-E and 11-F to part 11-D. Make sure to position the parts in the orientation shown.
Step 4
Fit part 11-C to part 11-D with 2 CP screws.
Step 5
Fit part 11-G to part 11-H with 2 CP screws.
Step 6
Fit part 11-H to part 11-E with 1 CP screw.
Step 7
Cut part 11-I from the sprue as shown by the dashed red line.
Step 8
Fit part 11-I to part 11-D.
Step 9
Fit assembly B to part 9-A with 1 DM screw.
STAGE COMPLETE
STAGE 12 PARTS
Step 1
Fit part 12-E to part 9-A (stage 10) with 2 CM screws.
Step 2
Fit part 12-D to part 9-A.
Step 3
Make sure the part is positioned so that it overlaps the inner edge of the chassis. Fix the part to the chassis with 2 CM screws.
Step 4
Fit part 12-C into part 12-E.
Step 5
Fit part 12-B using 1 CM screw. Make sure to place 12-B in the orientation shown by the red line.
Step 6
Part 12-A has one end that is larger than the other. Hook the large end onto part 12-C as shown.
Step 7
Rotate part 12-B into place as shown then fix part 12-B with 1 CM screw.
Step 8
Push the part 12-A into place as shown.
Step 9
Fit part 12-B using 1 CM screw. Make sure to place 12-B in the orientation shown by the red line.
Step 10
Fit part 12-B as shown using 1 CM screw.
STAGE COMPLETE
STAGE 13 PARTS
Step 1
Fit part 13-E to part 9-A with 2 CM screws.
Step 2
Fit part 13-D to part 9-A.
Step 3
Make sure the part is positioned so that it overlaps the inner edge of the chassis. Fix the part to the chassis with 2 CM screws.
Step 4
Fit part 13-C into part 13-E.
Step 5
Fit part 13-B to the parts with 1 CM screw. Make sure to place 13-B in the orientation shown by the red line.
Step 6
Part 13-A has one end that is larger than the other. Hook the large end onto part 13-C as shown.
Step 7
Rotate part 13-B in place then fix with 1 CM screw.
Step 8
Push part 13-A into place as shown then fix with 1 GM screw.
STAGE COMPLETE
