Pack 07

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 46: Fitting the driver's seat brackets

      STAGE 46 PARTS

      Step 1

      Fit parts 46-A to part 38-A (stage 42) with 2 DM screws.

      a
      b
      c

      STAGE COMPLETE

      Stage 47: Fitting the driver's seat backrest

      STAGE 47 PARTS

      Step 1

      Part 47-A has 10 screw holes in the canvas (circled). You may need to slightly widen some of the holes before fitting the part, as shown in image b.

      a
      b

      Step 2

      Fit the edge of part 47-A to part 46-B (stage 46) with 4 EM screws, as shown.

      a
      b

      Step 3

      Lower part 47-A into position, then press it onto part 46-B, as shown.

      a
      b

      Step 4

      Attach the canvas at the sides with 6 EM screws. You may find it easier to insert the screw through the canvas first, as shown in image a.

      a
      b
      c

      STAGE COMPLETE

      Stage 48: Fitting the driver's seat

      STAGE 48 PARTS

      Step 1

      Fit part 48-B to part 46-B (stage 47) in the orientation shown.

      a
      b

      Step 2

      Fit part 48-A to part 46-B with 1 HP screw.

      a
      b
      c

      Step 3

      Fit part 43-A (stage 43) to part 38-A (stage 46).

      a
      b

      Step 4

      Fit part 46-B to parts 46-A with 2 DM screws.

      a
      b

      Step 5

      The driver's seat base can be lifted up, as shown.

      a

      STAGE COMPLETE

      Stage 49: Fitting the passenger seat brackets

      STAGE 49 PARTS

      Step 1

      Fit part 49-A to part 49-B with 1 DM screw.

      a
      b

      Step 2

      Fit the second part 49-A to part 49-B with 1 DM screw.

      a
      b

      STAGE COMPLETE

      Stage 50: Fitting the passenger seat backrest

      STAGE 50 PARTS

      Step 1

      Fit the edge of part 50-A to part 49-B (stage 49) with 4 EM screws, as shown.

      a
      b

      Step 2

      Press part 50-A onto part 49-B, then attach the canvas with 6 EM screws.

      a
      b
      c

      STAGE COMPLETE

      Stage 51: Fitting the passenger seat

      STAGE 51 PARTS

      Step 1

      Note the position of the "R" (circled) which indicates the correct orientation in Step 2.

      a

      Step 2

      Fit part 51-A in the orientation shown onto part 49-B (stage 49) with 1 JP screw.

      a
      b
      c

      Step 3

      Fit the passenger seat to part 38-A (stage 50) with 2 DM screws.

      a
      b
      c

      STAGE COMPLETE

      Stage 52: Preparing the firewall

      STAGE 52 PARTS

      Step 1

      Insert part 52-B into part 52-A.

      a
      b

      Step 2

      Hold part 52-B in place as shown, while fitting part 52-C to part 52-B.

      a
      b
      c

      STAGE COMPLETE

      Stage 53: Fitting the firewall

      STAGE 53 PARTS

      Step 1

      Fit part 53-B to part 53-C.

      a
      b

      Step 2

      Fit part 53-B to part 52-A (stage 52) with 1 CP screw.

      a
      b
      c

      Step 3

      Fit part 53-A to part 52-A with 1 BP screw.

      a
      b
      c

      Step 4

      Fit the assembly to part 38-A (stage 48) with 3 BM screws.

      a
      b
      c

      Step 5

      Building a jerry can

      Fit part 53-D to part 53-E with 2 DP screws.

      a
      b

      Step 6

      Fit parts 53-H to part 53-D.

      a
      b

      Step 7

      Fit part 53-F and part 53-G to complete the jerry can, as shown.

      a
      b
      c

      STAGE COMPLETE

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