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 Rank: Super-Elite        Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,618 Points: 14,014 Location: ipswich
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STAGE 3A:
Left gearbox.
Locate the half shaft parts 3B, 3C and 3D.
Fit the universal joint, part 3D between the arms (the yoke) of the half shaft part 3C and fix in place using 1 x SM screw from each side.
Do not over tighten the screws as the parts need to be able to move.
Fit the other part of the half shaft, 3B in place as before and fix in place using 1 x SM screw from each side.
Do not over tighten the screws as the parts need to be able to move.
Locate the left gearbox part, 3A and fit the short end of the assembled half shaft in the hole in the side and fix from the inside using 1 x AM screw.
Do not over tighten the screw as the parts need to be able to move.
Fit the gearbox end plate, part 3E in place and fix using 2 x SM screws.
The parts will only fit one way.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,618 Points: 14,014 Location: ipswich
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STAGE 3B:
Locate the motor housing plate and detail part, 3F and 3H.
Fit the detail part in place on the housing plate and fix from the other side using 1 x AP screw.
The parts will only fit one way.
Locate water pump, part 3G and fit this in place on the housing plate.
Fix from the other side using 1 x AP screw.
The parts will only fit one way.
Fit the housing bracket, part 3J to the inside of the housing plate and secure with 2 x AP screws.
Fit the water pipe, part 3I to the outlet on the water pump, part 3J.
The end of the pipe will go behind the housing plate.
Store the assembled parts safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,618 Points: 14,014 Location: ipswich
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STAGE 4A:
Right gearbox.
Locate the half shaft parts 4B, 4C and 4D.
Fit the universal joint, part 4D between the arms (the yoke) of the half shaft part 4C and fix in place using 1 x SM screw from each side.
Do not over tighten the screws as the parts need to be able to move.
Fit the other part of the half shaft, 4B in place as before and fix in place using 1 x SM screw from each side.
Do not over tighten the screws as the parts need to be able to move.
Locate the right gearbox part, 4A and fit the short end of the assembled half shaft in the hole in the side and fix from the inside using 1 x AM screw.
Do not over tighten the screw as the parts need to be able to move.
Fit the clutch lever, part 4L into the two locating holes on the end of the right gearbox housing, part 4A.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,618 Points: 14,014 Location: ipswich
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STAGE 4B:
Fit the clutch pump and spring, parts 4I and 4J together, hooking each end of the spring into the locating tabs.
Fit the assembly in place on the gearbox housing in the two lower holes near the clutch lever just fitted.
Fit the shift lever cover parts 4G and 4H together.
They will only fit one way.
Fit the shift lever, part 4F into the hole in the side of the shift cover, part 4G.
It will only fit one way.
Secure from the inside using 1 x AP screw.
Fit this assembly to the side panel, part 4E and secure from the inside with 1 x AP screw.
IMPORTANT NOTE:
It is not mentioned in the printed instructions.
You need to keep the spare AM screws for use in stage 5 for assembling the gearbox.
Store the assembled parts safely for now.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,618 Points: 14,014 Location: ipswich
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STAGE 5A:
Assembling the gearbox and distributor.
Pic 1: Cut the clear tube 4M from the previous stage into 3 pieces – 50mm, 70mm and 130mm.
Pic 2: Fit the 50mm and 70mm pieces of tube as shown to the connector, part 4K from the previous stage.
Pic 3: Feed the 130mm piece of tube through the two holes in the top side of the right gearbox half, part 4A as shown, so that the front end of the tube extends slightly longer than the rear part.
Pic 4: Fit the two ends of the tube to the connector, part 4K.
Pic 5: Fit the two gearbox halves, 3A and 4A together and secure them using 2 x AM screws saved from the previous stage.
NOTE: This is not mentioned in the printed instructions.
Pic 6: Press the side plate, part 4E in place on the side of the gearbox.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,618 Points: 14,014 Location: ipswich
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STAGE 5B:
Pic 7: Fit the end of the 70mm tube to the small pin on the top of the gearshift cover, part 4G.
Pic 8: Locate the distributor cap and fittings, parts 5E, 5I and 5J.
Note that the fittings on the end of the sprue, 5J are different to all the others, 5I.
Pic 9: This picture shows the difference in these parts.
Pic 10: Carefully fit the centre connectors, parts 2 x 5J to the two centre pins on the distributor cap, part 5E.
Pic 11: Now fit all the connectors, parts 5I to the pins all the way around the distributor cap.
BUILDERS TIP: You might find it easier to fit each part while still connected to the sprue and carefully cut it free with a sprue cutter or similar afterwards.
This is entirely at the builder’s discretion.
Pic 12: This shows the completed cap.
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Rank: Super-Elite Groups: Official Builds, Administrators, Moderator, Global Forum Support, Registered Joined: 04/06/2011 Posts: 4,618 Points: 14,014 Location: ipswich
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STAGE 5C:
Pic 13: Fit the distributor body parts 5C and 5H together and fix with 1 x MP screw.
Pic 14: Fit the shaft, part 5B through the assembly as shown.
Pic 15: Fit the distributor body in place and secure through the top using 1 x AP screw.
The parts will only fit one way.
Pic 16: Fit the bracket, part 5G to the side of the distributor and fix with 1 x KP screw.
The bracket will only fit one way.
Pic 17: Fit the second bracket, part 5F to the bracket just fitted and fix with 1 x AAP screw.
The bracket will only fit one way.
Pic 18: Retrieve the assembled distributor cap and press-fit it onto the assembled distributor.
The parts will only fit one way.
Pic 19: This shows the completed stage.
Store the assembled parts safely for no
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