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.

      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 31: Fitting the front right wheel

      STAGE 31 PARTS

      Step 1

      Fit part 31-A to part 9-A with 2 FM screws.

      a
      b
      c

      Step 2

      Fit part 31-B to part 31-A and part 9-A with 2 DM screws.

      a
      b

      Step 3

      Take the wheel assembled in stage 25. Carefully remove part 25-C and retrieve part 25-D.

      a
      b

      Step 4

      Fit the wheel to part 18-B, then insert part 25-D as shown. Fix the parts together with an OM screw.

      a
      b
      c

      Step 5

      Fit part 25-C to the wheel.

      a
      b

      STAGE COMPLETE

      Stage 32: Fitting the voltage regulator and the battery

      STAGE 32 PARTS

      Step 1

      Fit part 32-A to part 31-A with 4 SM screws, ensuring the part is in the orientation shown.

      a
      b

      Step 2

      Fit part 32-B to part 31-A with a CP screw.

      a
      b
      c

      Step 3

      Building a jerry can

      Fit part 32-C to part 32-D with 2 DP screws.

      a
      b

      Step 4

      Fit parts 32-G to part 32-C.

      a
      b

      Step 5

      Fit part 32-E and part 32-F to complete the jerry can as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 33: Fitting the radiator

      STAGE 33 PARTS

      Step 1

      Fit part 33-B to part 33-A with 2 EP screws.

      a
      b

      Step 2

      Fit part 33-C to the assembly with a CP screw.

      a
      b
      c

      Step 3

      Fit the radiator assembly to part 9-A with 2 CP screws.

      a
      b
      c

      Step 4

      Fit part 33-D to the radiator.

      a
      b

      STAGE COMPLETE

      Stage 34: Fitting the engine and the radiator grille

      STAGE 34 PARTS

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

      Step 1

      Fit parts 34-F to part 9-A as shown.

      a
      b
      c

      Step 2

      Take part 34-E and cut one piece to 4 cm (34-E1) and cut another piece to 7 cm (34-E2).

      a
      b

      Step 3

      Fit part 34-E1 and part 34-E2 to parts 34-D as shown.

      a
      b
      c

      Step 4

      Fit part 34-E1 to part 31-A.

      a
      b

      Step 5

      Fit part 34-D to part 32-B.

      a
      b

      Step 6

      Fit part 34-E2 to the engine assembly (stage 08) as shown.

      a
      b

      Step 7

      Fit the engine assembly to the chassis assembly, positioning the exhaust pipe underneath the steering gear (circled in blue), then fix the parts together using 2 FM screws and a DM screw.

      a
      b
      c

      Step 8

      Fit the second part 34-D to part 32-B.

      a
      b

      Step 9

      Fit the radiator grille assembly (stage 01) to the chassis assembly, carefully pushing part 1-K into place using a screwdriver or similar tool (image b).

      a
      b
      c

      Step 10

      Fix the parts from underneath using a DM screw, then fix them from each side using 2 DM screws and 1 CM screw.

      a
      b
      c

      Step 11

      Fit part 34-C to the engine as shown.

      a
      b

      Step 12

      Fit the other end of part 34-C into the radiator from underneath, as shown.

      a
      b

      Step 13

      Fit part 34-B to the assembly with 3 EM (B) screws.

      a
      b

      Step 14

      Fit part 34-A to part 11-B with 2 EM (Y) screws.

      a
      b

      STAGE COMPLETE

      Stage 35: Building the theodolite

      STAGE 35 PARTS

      Step 1

      Fit part 35-E to part 35-D.

      a
      b

      Step 2

      Fit part 35-B to part 35-E.

      a
      b

      Step 3

      Fit part 35-C to part 35-B.

      a
      b

      STAGE COMPLETE

      Stage 36: Fitting the rear left wheel

      STAGE 36 PARTS

      Step 1

      Fit part 36-F to part 36-B with 2 CM screws.

      a
      b

      Step 2

      Place part 35-A in a bowl of hot water to soften it. After 1–2 minutes, remove part 35-A with tweezers, then dry with a cloth.

      a

      Step 3

      Fit part 36-A to part 35-A.

      a
      b

      Step 4

      Fit part 36-B to part 36-A, ensuring the screw holes are aligned (circled). Squeeze the parts together and fix with 4 BM screws.

      a
      b
      c

      Step 5

      Fit the wheel to part 21-A, then insert part 36-E as shown. Fix the parts together with an OM screw.

      a
      b
      c

      Step 6

      Fit part 36-C to the wheel.

      a
      b

      Step 7

      Fit part 36-D to part 36-C.

      a
      b

      STAGE COMPLETE

      Stage 37: Fitting the front bumper

      STAGE 37 PARTS

      Step 1

      Fit part 37-A to part 9-A with 8 DM screws as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 38: Fitting the towing hook

      STAGE 38 PARTS

      Step 1

      Fit part 38-D into part 38-C with a CP screw.

      a
      b

      Step 2

      Fit part 38-C to part 38-B with a CP screw.

      a
      b

      Step 3

      Fit the towing hook to part 9-A with 2 CM screws.

      a
      b

      STAGE COMPLETE

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