Build your own THUNDERBIRD 2

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Godfrey Taylor
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STAGE PAGE 74 Tailwing ramjets and Cobra Half-track 247 75 Tailwing intakes 250 76 Tailwing fins 253 77 T2 control board 255 78 T2 wings and Mobile Crane 258 79 T2 side frames and

Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE.. Published in the USA by De Agostini Publishing USA, Inc., 121 E.

2 STAGE PAGE 74 Tailwing ramjets and Cobra Half-track Tailwing intakes Tailwing fins T2 control board T2 wings and Mobile Crane T2 side frames and Mobile Crane Complete your Thunderbird 2! 264 Troubleshooting guide 267 Editorial and design by Continuo Creative, North Road, London N7 9DP. Published in the UK by De Agostini UK Ltd, Battersea Studios 2, 82 Silverthorne Road, London SW8 3HE.. Published in the USA by De Agostini Publishing USA, Inc., 121 E. Calhoun Street, Woodstock, IL All rights reserved 2017 Warning: Not suitable for children under the age of 14. This product is not a toy and is not designed or intended for use in play. Items may vary from those shown.

3 STAGE 74 TAILWING RAMJETS YOUR PARTS Tools and materials: Superglue + COBRA HALF-TRACK Tailwing lower Backing R Backing L Ramjet covers x 4 Backings C x Front Familiarise yourself with the lower 02 tailwing part. The left and right backings are marked with an L and an R. Back Glue one of the ramjet covers to the right backing, like this. Repeat for the left backing. Now do the same for the central (C) backings like this. 247

4 Back Find these downward-facing hooks on the backings. Front Glue the right ramjet and backing to these notches at the right-rear of the lower tailwing. The backing s hooks will hold it in position, like this. Glue the central parts here and here. Then glue the left one in place. All four should look like this. STAGE COMPLETE COBRA HALF-TRACK Tools and materials: Superglue, tweezers Headlights Windscreen Searchlights x 2 Canopy Seat Bulkhead Dashboard Steering wheel Roll cage Jerry cans x 2 Canvas packs x 2 Bonnet rails x 2 Planks x Glue the steering wheel to the dashboard. All details will be glued. It should be level, like this. Now glue the dashboard to the main body. The seat goes here. 248

5 The bulkhead sits just behind the seat. These parts should be level with each other, like this. The roll cage fits here like this Fit the headlights like this. Fit the first bonnet rail to these holes. It should be level Repeat for the other side. Glue the windscreen here. Now fit one searchlight here and the other one next to it Fit the canvas packs to both sets of planks. Glue one of the two jerry cans here with the pack/plank assembly behind it. They should sit like this STAGE COMPLETE Repeat for the other side. Finally, glue the canopy to these holes. The assembly is complete. 249

STAGE 75 TAILWING INTAKES YOUR PARTS Tools and materials:

L Intakes C x 2 Screws x 7 01 Front Familiarise yourself

02 Locate the R and L marks on the right and left intakes.

These will be glued into the intakes vertical grooves, via

6 STAGE 75 TAILWING INTAKES YOUR PARTS Tools and materials: Superglue Tailwing upper Intake fins x 48 Intake R Intake L Intakes C x 2 Screws x 7 01 Front Familiarise yourself with the upper tailwing part. 02 Locate the R and L marks on the right and left intakes. Back 03 Carefully separate the fins from the sprues. These will be glued into the intakes vertical grooves, via their central pins (arrow). 04 This is what each fin will look like. This is the right intake. 250

7 05 Keep fitting the fins until 11 are fitted, like this Now begin adding fins to the left intake, in the same way. Keep adding the fins until again there are 11 in position Now repeat for the first of the central (C) intakes. Eleven fins will fit like this. Repeat for the other central intake, and 11 more fins. 13 Again, there are hooks to hold 14 the intakes. Front Glue the right intake to these notches on the lower tailwing part, assembled in the previous stage. 251

8 15 The intake will sit like this. 16 Glue the first central intake next to the right one And then the other one next to that. The left intake will fit here. The intakes should look like this Lower this stage s upper tailwing part onto the lower one, matching the arrowed mounting posts and holes. The parts should join neatly, like this. Fit a screw here, and tighten lightly STAGE COMPLETE Fit the rest of the screws in this order, tightening each lightly at first. Now tighten all the screws fully. 252

Both ducts are thinner at the front end.

9 STAGE 76 TAILWING FINS YOUR PARTS Tools and materials: Superglue Duct L Duct R Tailwing fin L Tailwing fin R Note the L and R markings on the insides of the ducts. Slot the tailwing s side block into this slot in the left tailwing fin. It should sit comfortably, like this Front... and be flush with the side of the tailwing, angled down and inwards, as shown. Prepare the left duct. Both ducts are thinner at the front end. 253 Fit the duct over the protruding tailwing block, sealing in the fin. Use a little glue to secure the parts.

10 Make sure the duct is flush with the side of the tailwing. Repeat for the right fin. Again, its side block will locate it And the right duct will secure it, with a little glue to strengthen the hold. The tailwing fins are now complete. STAGE COMPLETE 254

STAGE 77 T2 CONTROL BOARD YOUR PARTS Tools

board Screws x 4 Extension cable (for cockpit

its connector with its barb pointing upwards.

11 STAGE 77 T2 CONTROL BOARD YOUR PARTS Tools and materials: Tweezers, screwdriver Control board Screws x 4 Extension cable (for cockpit LED) In this stage, you will need your model s cockpit and nose assembly. Locate the LED s yellow cable, and position its connector with its barb pointing upwards. Fit this connector into the socket end on this stage s extension cable. The barbs will fit into the corresponding slots, securing the join. 04 Check that the cables are firmly 05 connected. The cockpit is now ready to be wired up. 255

06 07 08 Make sure there are no batteries in

using tweezers to carefully pull this cable

Now remove the three screws securing the

You are now ready to fit the control board.

Cockpit LED (headlight) Lower-limit switch

to them, and are also annotated in the photo

Left booster LED (taillight) Battery box

switch Booster speaker 12 Lay the control

12 Make sure there are no batteries in your model s battery box, and that the switch is in the OFF position. You will now remove the test board: begin by using tweezers to carefully pull this cable s connector out from its socket like this Do the same for all the cables connectors. Now remove the three screws securing the test board to your model. You are now ready to fit the control board. Motor socket Upper-limit switch (Front) Cockpit LED (headlight) Lower-limit switch Familiarise yourself with the final control board. The sockets have descriptions printed next to them, and are also annotated in the photo shown here. Left booster LED (taillight) Battery box (power) Right booster LED (taillight) Main switch Booster speaker 12 Lay the control board out where the test board was, noting which side the front of the board is. Fit one of this stage s screws into this hole and tighten it. 13 Fit two more of the screws to secure the board. 256

13 Fit the main switch cable s connector into the socket marked switch. Make sure you select the correct cable, and that it clicks firmly into its socket. Now fit the battery box cable s connector into the socket marked power. Ensure it is fitted securely Now fit the left booster s LED cable into the next socket along, which is marked taillight. Check all three connectors fiited so far are secure. Now fit the legs upper-limit switch cable into the socket marked upper limit Next to this goes the motor s cable. 23 Check all five connectors fitted so far are secure On the right side of the board, fit the right booster s speaker cable (you marked this with tape during the booster assembly) into the socket marked speaker. STAGE COMPLETE The right booster s LED cable will slot in next to it. The legs lower-limit switch cable will fit into the socket marked low limit 257 That completes the wiring up of the control board for now.

14 STAGE 78 T2 WINGS YOUR PARTS Tools and materials: Tweezers + MOBILE CRANE Wing L Wing R Fixing joints x 2 Red and blue wingtip lights Note the L and R markings on the inner edges of the two wings. Fit the red wingtip light to the front tip of the left wing. It will look like this. You do not need to glue this part Now fit the blue light to the tip of the right wing. Do not glue the part. The wings are now complete. 258

15 07 Top Note the shape of the two fixing joints. At the bottom, you will see a T-shaped pin. Fit the first joint to this slot, on the left side of your model. Match the T-shaped pin with its recess. Press the part into place STAGE COMPLETE It should sit neatly in the recess, like this. MOBILE CRANE Tools and materials: Tweezers, superglue Repeat for the right side, again matching the T-shaped pin/recess. The joints are ready. Warning bar Wheel inners x 6 Wheel outers x 6 Bumper Main body Tyres x 12 Axles x Glue a wheel inner to a wheel outer, like this. Repeat for all the wheel inners and outers. Now glue one wheel set to the central recess in a tyre like this. Repeat for all six wheel sets. 259

16 Now begin fitting another tyre to each of the six wheel/tyre sets so all six are prepared. Fit one set to an axle tip. Repeat for the remaining two axles. 09 The main body came preassembled, but if you need to, glue its parts together via these posts. 10 Fit the first axle here Seal it in with a free wheel set. Press these together then repeat for the others. 14 Top Note the shape of the warning bar and bumper. 15 Glue the bumper here, making sure it is the right way up. Top 16 Then fit the warning bar to it. STAGE COMPLETE 260

17 STAGE 79 T2 SIDE FRAMES YOUR PARTS + MOBILE CRANE Side frame R Side frame L Screws x Temporarily disconnect the LED extension cable from the cockpit s LED cable. 04 Now fit its connector to the free socket on the control board, marked headlight. 05 Run the extension cable along the left inside of your model, clipping it between these pins as you do. 06 Keep going until the cable is fitted neatly, like this. 07 Go back and check all the pins are holding the cable safely in place. 08 If the cable still lifts at all, secure with a few bits of tape. Use a low-tack masking tape for this. 09 With the cockpit/nose asembly face down, line up the right side frame. Position the parts like this. Turn the side frame as you join the parts, so its mounting lug (circled, left photo) sits on top of the cockpit s smaller one (circled, right photo). 261 Secure the lugs with a screw.

18 10 11 Build your own STAGE COMPLETE Make sure the join is neat, and that the contours of the parts match. Repeat for the left side frame. MOBILE CRANE Tools and materials: Tweezers, superglue Front unit Cockpit Light mount Crane arm A Hydraulic bar Crane base Intake Crane mount Searchlight Pivot A Hinge pin Crane arm B Pivot B Aerial Intake base Headlights x 2 Nameplates x 2 Platform base Handrail The hydraulic bar will adhere to these holes on the crane arm B. Now slot the tip of crane arm A into the hinge of arm B (arrowed). Do not glue these parts. Use tweezers to fit the hinge pin into the hole joining the arms. Press the pin into place with the back of the tweezers. Again, do not glue these parts. Now glue the platform base to the end of the crane arm A, via its pins. From this point, all details will be glued Front The handrail completes the platform assembly. This photo shows the handrail s correct orientation. Now glue the intake to the intake base. 262 Glue the pivot B to pivot A, like this.

19 Glue the front unit to the forward section of the main body. The crane mount will sit behind it. The cockpit fits here, facing forwards The crane base will clip into place here. The intake assembly will fit here, pointing forwards. The nameplates will fit in these holes, facing outwards. Fit both Glue the pivots to these holes and this slot. 18 Now clip the crane itself into its base. 19 The pin at the top of the pivots will locate and hold the crane s upper length. Glue these parts. 20 The headlights go here, so fit both now. The light mount will sit in this hole with the searchlight in the mount s hole STAGE COMPLETE Check that the angle of the searchlight and its mount are as shown above. The aerial fits next to the searchlight. 263

20 STAGE 80 Build your own COMPLETE YOUR YOUR PARTS Tools and materials: Superglue, screwdriver, towel/soft cloth! Rear body panel Controller face Joint plate Light block Controller body A-B buttons C-D buttons Medium screws x 3 Large screws x 18 Small screws x Join the rear body panel to the back of the side frames, via the arrowed posts. There should be no gaps. Turn the assembly over and secure the posts with two of the large screws Both should be securely tightened The rear panel is complete. Reconnect the cockpit LED cable to the extension cable. Then lower the upper body onto the lower body gently. Make sure the missile launcher spring and its tube engage neatly. Temporarily fasten the upper and lower parts with bits of masking tape. 264

21 Lay your model gently on a towel or soft cloth, face down, then tighten another larger screw into this hole. 12 Now work around all of the circled holes, in a random, criss-crossing order as you have previously, to ensure even pressure is achieved. 13 Tighten each screw fully, then place your model back the right way up. 14 Take the assembled right wing (with T2 insignia and blue light) and glue it into the right-side slot. 15 The wing should fit neatly, pointing forwards, like this. 16 Repeat for the left wing. 17 It, too, should point forward. Next, slot the fins of the tailwing into these longitudinal slots. You just have to fit either Pod 3 or 4, and your model is complete! All that s left to do is prepare the remote control Top Begin this process by slotting the joint plate into place on the controller body. Note its orientation (inset). Make sure the part is seated correctly. 265 Now fit the light block into this hole, in the controller face.

position, join the controller body to the

22 Secure this with a small screw. The A-B buttons will sit in the arrowed holes, without glue. Check the front side of the face to ensure that they are positioned like this. The C-D buttons fit here, without glue The four buttons should look like this from the front. 29 Making sure the plate remains in position, join the controller body to the face, like this. Secure it with a medium screw. Repeat for the opposite hole. YOUR RESCUE COLLECTION IS NOW COMPLETE! The controller is complete. It will need two AAA batteries. The rest of this page explains how to use the remote. Boosters Button A activates the boosters red lighting and engine sound effects. Missile launcher The missile launcher is operated manually: slide the hatch back and the missile launcher will spring up through the hole. Pods The pods are not physically attached to the T2 body frame, so when handling the model, use two hands to clasp both the body and the pod. 266 Using the controller Button A: Booster LEDs and engine sound. Button B: Cockpit LED. Button C: Extend telescopic legs (to raise T2). Button D: Retract telescopic legs (to lower T2). Note: There is no ON/OFF switch on the controller, so remove the batteries when not in use.

TROUBLESHOOTING GUIDE PROBLEMS WITH THE CONTROLLER Check the batteries If none of the buttons

Insert three new AA batteries to the battery box, ensuring they are facing in the correct

Remove the 15 screws that connect the top and bottom sections of the main body panels.

When buttons A to D are pressed, the controller s LED will light up red, indicating that the

Turn the power ON and check whether the LED on the circuit board lights up.

seated in its socket (arrowed) securely.

boosters do not light up when button A is pressed, check that the wires leading from both are

If the cockpit interior LED does not light up when button B is pressed, check the wiring

23 TROUBLESHOOTING GUIDE PROBLEMS WITH THE CONTROLLER Check the batteries If none of the buttons respond Check that the main switch on your T2 model is OFF. Insert three new AA batteries to the battery box, ensuring they are facing in the correct direction. Remove the 15 screws that connect the top and bottom sections of the main body panels. See Step 10 of Stage 80 (Pack 12). The controller does not have an ON/OFF switch. When buttons A to D are pressed, the controller s LED will light up red, indicating that the unit is functioning. Turn the power ON and check whether the LED on the circuit board lights up. If the LED does not light up, check that the connector at the end of the battery box cable is seated in its socket (arrowed) securely. If the LED does not light up, insert two new AAA batteries, making sure to face them in the correct direction. See Stage 77 (Pack 12). If button A doesn t respond If button B doesn t respond If buttons C & D don t respond If the boosters do not light up when button A is pressed, check that the wires leading from both are linked into their respective sockets securely. Reset their connectors if either is loose. If the cockpit interior LED does not light up when button B is pressed, check the wiring leading from the cockpit to the control board including its extension cable s connector. If the telescopic legs do not extend and/or retract when buttons C and D are pressed, or if the motor at the front of the unit does not function at all, check the motor s wiring and connector. If the engine sound effects cannot be heard when button A is pressed, it is the speaker s cable and connector that should be checked and reset. 267

Build your own PROBLEMS WITH THE TELESCOPIC LEGS Your Thunderbird 2 s telescopic legs are powered by the motor at the

turn combine to move the legs rail-gears. If any problems occur, follow the steps found on this page.

securely with the teeth of their centre gear, at all four points of contact.

Check the rail-gear racks and inner springs Check that each of the four rail-gear racks are correctly attached to their

determined by the upper-limit switch, fitted to the slide rail.

s wiring and connectors. See Step 20 in Stage 45 (Pack 07).

24 Build your own PROBLEMS WITH THE TELESCOPIC LEGS Your Thunderbird 2 s telescopic legs are powered by the motor at the front of the main body unit, which branches left and right to operate the drive shafts, crown and centre gears, which in turn combine to move the legs rail-gears. If any problems occur, follow the steps found on this page. Check the centre gear and rail-gear racks teeth/notches Check that the notches on the legs rail-gear racks are engaged securely with the teeth of their centre gear, at all four points of contact. Adjust both rail-gear racks at the same time if anything is amiss. See Steps 1 11 in Stage 46 (Pack 08). Check the rail-gear racks and inner springs Check that each of the four rail-gear racks are correctly attached to their inner springs. This is especially important for the right-side racks, as these were removed and reinstalled in Stage 45. See Stage 45 (Pack 07). Check the limit switches Check the motor unit installation The raising of your T2 model on its telescopic legs is determined by the upper-limit switch, fitted to the slide rail. If there is a problem with this operation, check the upper-limit switch s wiring and connectors now. See Step 19 in Stage 44 (Pack 07). Similarly, the lowering operation is controlled by the lower-limit switch, so if this is the problem check this component s wiring and connectors. See Step 20 in Stage 45 (Pack 07). Check the guide pins It is possible that the guide pins may have come loose during the assembly, which can affect the smooth operation of the legs. It is a good idea to check that all four of the guide pins fitted are still securely in place. See Stages 44 and 45 (Pack 07). Check the gears and drive shaft installation The connection between the gears that carry the power from the motor unit to the legs themselves must be properly engaged to ensure smooth operation. Check that the crown gears, pinion gears and drive shafts connecting the motor unit and gearbox are all correctly installed. A fault with the motor, for example if it is loosely fitted, will prevent the legs moving as intended, so go back and check that the motor unit is tightened securely with three screws. See Step 06 in Stage 43 (Pack 07). Check the slide rails Check that the right and left slide rails are tightened securely with all six screws, as any looseness in these parts will affect the legs operation. See Stages (Packs 06 & 07). See Stages 44 and 45 (Pack 07). 268

Build your own THUNDERBIRD 2

Build your own THUNDERBIRD 2 PACK 11 PAGE 67 Pod 4 ramp tracks and Jet Air Transporter 224 68 Left rear booster and Alan s Racing Car 227 69 Right rear booster and Alan s Racing Car 230 70 Left booster speaker 233 71 Right rear booster