DB5, Pack 8

[Mark A]

Stage 58, Building the engine bay right wall

 

We start pack 9 with a bit of corrective surgery to the rear suspension. Start by removing the rear chassis assembly, then remove the rear suspension assembly. Rotate the suspension assembly 180 degrees, and reinstall. Then replace the chassis assembly and reinstall the 3 DS02 screws.

 

We start the engine bay assembly by building the vacuum assist pump. Usings parts 58-C and 58-B, assemble the pump, and secure with a PS05 screw.

Next, install the J connector to the pump.

The next step is to mount the bit of vinyl pipe to the T connector. This is then mounted to the pump assembly.

Lastly, the pump assembly is mounted to the right wall of the engine bay. This is held in place with 2 PS11 screws from the back side of the wall.

Stage complete.

 

[Mark A]

Stage 59, building the firewall

 

Start by selecting one of the two canisters. They are identical, so it doesn't matter which you choose. Place it into position on the firewall, then position the second canister the same way. Secure these from the back side of the firewall with 2 PS05 screws.

 

Next, screw the angled firewall part to the firewall with a PS05 screw.

Now, take the two canister caps, and press them into the canisters. Again, they are identical, so either will work.

 

Lastly, fit the sidewall to the firewall, noting the two screw posts, and the locating pin. Once fitted into position, use 2 PS11 screws to secure into position.

Stage finished!

[Mark A]

Stage 60, building the engine bay left wall

 

This is a fast stage. Start by fitting the pump onto the pump mount, then fit the pump to the sidewall. Then, Mount the sidewall to the firewall as in the previous stage.

 

Stage finished.

[Mark A]

Stage 61, Fitting the speaker and tank

 

Start by placing the speaker into position. The wires should face to the left. Next, place the horseshoe shaped speaker retainer into position, and secure with 2 PS05 screws.

Next, using the long piece of tubing, press one end of the tube onto the T shaped fitting on the right side of the firewall assembly.

Route the pipe between the sidewall, and the rectangular box.

Now, using the short piece of tubing, press one end onto the pin found on the firewall. Then route the tube down the same path as the longer piece of tubing.

Lastly, we assemble and mount the tank. Start by mounting the filler cap to the upper half of the tank. secure from the underside with a PS05 screw. Then, place the lower tank half into position, and secure with another PS05 screw.

Finally, mount the tank into position on the sidewall, and fix into position with 2 PS05 screws.

Stage finished.

[Mark A]

Stage 62, Fitting the starter coil and pipes

 

 

We start with the washer fluid tank. Start by adding the fitting to the tank lid. This is a press fit, and can only fit on one way.

 

Next, fit the lid onto the tank, and secure with e PS14 screw from the inside.

 

Now, mount the tank holder to the tank, aligning the locating pin with the hole in the holder. Then, mount the holder to the sidewall in its position and secure from the underside with another PS14 screw.

 

We now turn our attention to the starter coiland related pipework. Start by connecting the green hose with the L fitting, then press the opposite end onto the voltage regulator.

Fit the starter coil into position. Note that one of the pins is shaped, so it will only go on one way.

Lastly, fit the large hose into position. One end goes to the firewall, and the other to the side wall.

 

Stage finished!

[Mark A]

Stage 63, fitting the air filter, mounting the engine, and fixing the interior floor

We start with the air filter. Form the metal mesh into a circle, and place it into the housing. I formed it by rolling my exacti knive on the mesh while on a stack of paper. The paper compresses enough that the mesh will take on a circular shape.

Fit the mesh to the lower housing, then place the upper half into position, Secure it with 2 PS14nscrews. Next, add the filter mount.

Cfter the filter mount is installed, add the air hoseto the filter. This clips into place solidly.

Next, position the air filter in the engine bay, and secure with 2 more PS14 screws.

Next, add the pipe to the water tank.

Nnext up is mounting the engine bay to the chassis. Care must be taken to align the steering shaft properly. The bay is secured with 6 DS02 screws.

The motor is now set into place. The only real trick here is getting the drive shaft into the transmission. It is secured with 3 DS02 screws.

Now, to attach all the various hoses and wires in the engine bay. Start with the green hose that has the L shaped connector on it. Fit the connector into the center hole on the distributor.

 

Followed by the long water pipe, and the short hose;

 

Next, fit the fuel line to the T connector.

 

Now, as per the directions, fit the interior to the chassis. The pictures in the build guide are exemplary in showing how to position it in place. (I couldn't photo the process...only 2 hands...)

Position the wires in the clips as directed, and route the left and right hand wires in the channels.

 

Stage finished

 

[Wtshark]

Mark, 

Can you post a few photos of how your interior aligned in the chassis? I understand it's physically impossible to photograph the installation, (requiring both hands to install) but I'd like to compare your results with mine. Is it compressed? How "deep" did the back settle into the chassis?

Thanks!

[Mark A]

On 8/2/2024 at 5:28 AM, Wtshark said:

Mark, 

Can you post a few photos of how your interior aligned in the chassis? I understand it's physically impossible to photograph the installation, (requiring both hands to install) but I'd like to compare your results with mine. Is it compressed? How "deep" did the back settle into the chassis?

Thanks!

Hi! I am not entirely sure if the pics I took will answer your question, but here goes! My interior sat right down on the chassis, and I don't recall any issues getting it installed

[Mark A]

Stage 64, Building the mine dispenser

This stage is mostly about installing the battery box. I failed to take pics of the two parts of the mine box going together, but its self explanitory, and I ran into no issues.

 

The battery box is then installed, with the bay facing upwards. Connect the two cables after routing them up the right side of the engine bay.  and put the cover on the battery bay.

 

[Mark A]

Stage 65, fitting the mine dispenser

This stage results in a complete mine dispenser.

Start by adding the dual pipe connector, and secure it with 2 PS21 screws.

 

Next are the two piston assemblies. sort left from right and align as per the directions. Secure each with 2 more PS21 screws.

 

Now, add the two pieces of tubing, that lead from each piston to the pipe connector.

Next, insert the piston rods into each piston.

Now, using the assembly from stage 64, align it with the assembly we just finished. hook the ends over the pistons, and secure with PS02 screws.

Now, connect the various cables as directed, and place the compartment cover onto the mine dispenser.

[Mark A]

Stage 66, fitting the exhaust pipes

This is a super quick stage.

 

Start by joining the two halves of the exhaust. secure with 4 PS20 screws. Then, fit the chrome tailpipes onto the exhaust pipes.

 

Lastly, insert the exhaust piped into the mufflers, and secure with a DS01 screw.

[Wtshark]

18 hours ago, Mark A said:

Hi! I am not entirely sure if the pics I took will answer your question, but here goes! My interior sat right down on the chassis, and I don't recall any issues getting it installed

Thanks Mark, 

Can you post a pic of the entire interior, from the side of the chassis? (like examples of mine) I appreciate you answering the question!

 

[Mark A]

Mine has the same space below the interior floor. (plus a little in fact) It will go away when the body is put on, so no worries!

 

Mark

[Wtshark]

18 hours ago, Mark A said:

Mine has the same space below the interior floor. (plus a little in fact) It will go away when the body is put on, so no worries!

 

Mark

Thanks