Pack 06

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 39: Building the gear lever

      STAGE 39 PARTS

      Step 1

      Slide part 39-C onto part 39-A, then push part 39-B to part 39-A.

      a
      b
      c

      Step 2

      Building a jerry can

      Fit part 39-D to part 39-E with 2 DP screws.

      a
      b

      Step 3

      Fit parts 39-H to part 39-D.

      a
      b

      Step 4

      Fit part 39-F and part 39-G to complete the jerry can as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 40: Fitting the gear lever

      STAGE 40 PARTS

      Step 1

      Insert the gear stick assembly (stage 39) to part 38-A (stage 38).

      a
      b

      Step 2

      Fit part 40-B into part 40-A.

      a
      b

      Step 3

      Fit part 40-A to part 38-A in the orientation shown, using 2 DM screws.

      a
      b

      Step 4

      Building a jerry can

      Fit part 40-C to part 40-D with 2 DP screws.

      a
      b

      Step 5

      Fit parts 40-G to part 40-C.

      a
      b

      Step 6

      Fit part 40-E and part 40-F to complete the jerry can as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 41: Building the transfer case levers

      STAGE 41 PARTS

      Step 1

      Fit part 41-C to part 41-A through the hole circled in blue, then fit part 41-B to part 41-A.

      a
      b
      c

      Step 2

      Building a jerry can

      Fit part 41-D to part 41-E with 2 DP screws.

      a
      b

      Step 3

      Fit parts 41-H to part 41-D.

      a
      b

      Step 4

      Fit part 41-F and part 41-G to complete the jerry can as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 42: Fitting the transfer case levers

      STAGE 42 PARTS

      Step 1

      Insert part 42-B into the transfer case lever assembly (stage 41).

      a
      b

      Step 2

      Fit part 42-A to the assembly with 2 BP screws.

      a
      b

      Step 3

      Insert the levers through the opening by squeezing them together, then fit the lever assembly to part 38-A with 2 DM screws as shown.

      a
      b

      Step 4

      Fit part 42-C to part 42-B.

      a
      b

      Step 5

      Building a jerry can

      Fit part 42-D to part 42-E with 2 DP screws.

      a
      b

      Step 6

      Fit parts 42-H to part 42-D.

      a
      b

      Step 7

      Fit part 42-F and part 42-G to complete the jerry can as shown.

      a
      b
      c

      STAGE COMPLETE

      Stage 43: Fitting the canvas cover and the jerry cans to the bonnet

      STAGE 43 PARTS

      Step 1

      Cut part 43-B from the sprue.

      a

      Step 2

      Fit part 43-B to part 43-A.

      a
      b

      Step 3

      Fit part 43-C to part 43-A.

      a
      b

      Step 4

      Take two parts 10-B (stage 10), and part 2-A (stage 2). Fit 10-B to 2-A using 2 AFM screws. Repeat to fit another part 10-B as shown.

      a
      b
      c

      Step 5

      Thread each strap through the buckles.

      a
      b

      Step 6

      Peel pieces of double-sided tape (parts 43-E) from the backing paper, then stick them to the ends of the straps as shown.

      a
      b
      c

      Step 7

      Fit two jerry cans under the straps as shown.

      a
      b

      Step 8

      Measure 4.5 cm on part 43-D as shown, then fold the fabric, and continue to fold the fabric to create the shape shown in image c.

      a
      b
      c

      Step 9

      Fit part 43-D under the straps as shown.

      a
      b

      Step 10

      Remove the backing paper from the double-sided tape, then pull the straps tight and press on the ends of the straps as shown.

      a
      b
      c

      Step 11

      Take the remaining three parts 10-B. Thread the straps through the buckles, then stick double-sided tape (parts 43-E) to the ends of the straps.

      a
      b
      c

      Step 12

      Fit parts 10-B to part 2-A with 6 AFM screws, ensuring the parts are in the orientation shown.

      a
      b

      Step 13

      Fit three jerry cans under the straps as shown.

      a
      b

      Step 14

      Remove the backing paper from the double-sided tape, then pull the strap tight and press on the end to stick it in place as shown.

      a
      b
      c

      Step 15

      Repeat this procedure for the other straps as shown.

      a

      STAGE COMPLETE

      Stage 44: Building the rear right wheel

      STAGE 44 PARTS

      Step 1

      Fit part 44-D onto part 44-A.

      a
      b

      Step 2

      Fit part 44-C to part 44-B with 2 CM screws.

      a
      b

      STAGE COMPLETE

      Stage 45: Fitting the rear right wheel

      STAGE 45 PARTS

      Step 1

      Place part 45-A in a bowl of hot water to soften it. After 1–2 minutes, remove part 45-A with tweezers, then dry with a cloth.

      a

      Step 2

      Fit part 44-A (stage 44) to part 45-A.

      a
      b

      Step 3

      Fit part 44-B (stage 44) to part 44-A, ensuring the screw holes are aligned (circled). Squeeze the parts together and fix with 4 BM screws.

      a
      b
      c

      Step 4

      Fit the wheel to part 21-A, then insert part 45-C as shown. Fix the parts together with an OM screw.

      a
      b
      c

      Step 5

      Fit part 45-B to the wheel.

      a
      b

      STAGE COMPLETE

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