pack 05 - us website · 2021. 2. 8. · 35 the vacuum pump in this stage you will add the vacuum...

PACK 05

STAGE P.

33 THE HEADLIGHTS – 1 75

34 THE HEADLIGHTS – 2 77

35 THE VACUUM PUMP 79

36 THE INDICATORS – R 83

37 THE FUEL FILTER 85

38 THE AIR FILTER 89

39 THE DIFFERENTIAL 91

40 THE DRIVESHAFT 93

41 THE ROTARY ENGINE 96

Designed and produced by Milanoedit srl – www.milanoedit.com

Published by De Agostini Publishing S.p.A., 28100 Novara, Via G. da Verrazzano 15All rights reserved © 2020

NOT SUITABLE FOR CHILDREN UNDER THE AGE OF 14.

THIS PRODUCT IS NOT A TOY AND MUST BE USED UNDER THE SUPERVISION OF AN ADULT.

ITEMS MAY VARY FROM THOSE SHOWN.

❷❶

❸❺

❹

❻

LEFT HEADLIGHT

TOOLS NEEDED• Cross screwdriver no. 1

RECOMMENDED TOOLS• Cloth• Flat file

CAM

THE HEADLIGHTS – 133

In this stage you will assemble the left headlight. You will also install a cam on the rotor of the 1:2 scale model of the rotary engine.

• Parts for the 1:8 scale Mazda Cosmo Sport model car • Parts for the 1:2 scale rotary engine

❶❷❸❹❺

❻Headlight frame A Headlight frame BHeadlight unitHeadlight lensScrews (2.3 x 4 mm) x3

Cam

Insert the linchpins on the headlight unit into the holes in part A of the frame, as shown in the photo. The pieces only fit together in one way.

Attach the piece you have just assembled to part B of the headlight frame.

Press until the pieces click into place.

Step

1

COSMO SPORT

The left headlight – 1

❶

❸

❷

LIST OF PIECES

Stage 33Pack 05

75

Step

2

COSMO SPORT

The left headlight – 2 Step

3

COSMO SPORT

The left headlight – 3

Step

4 The cam

Clean the headlight unit with a cloth so as not to leave any fingerprints.

Attach the lens to the headlight unit.

Use the photo to help you understand which

way the lens should face.

The left headlight assembled correctly.

Get the front end of the body (which you worked on in Pack 1) and attach the left headlight to it, as shown in the photo.

Get the rotor and insert the cam, as shown in the photo.

Turn the cam and rotor to make sure they work correctly.

Insert and tighten two of the screws that came with this stage in the holes circled in the photo.

If the pieces don’t turn easily, you can file the edge of the cam to eliminate any manufacturing defects.

This is the result of this easy assembly session. Keep all the pieces in a safe place.

The next stage

❻

❻

❹

ROTARY ENGINE

FINAL RESULT

Stage 33Pack 05

76

RIGHT HEADLIGHT

CAM MOUNT PLATE


RECOMMENDED TOOLS• Cloth

THE HEADLIGHTS – 234

In this stage you will assemble the right headlight. You will also continue working on your 1:2 scale model of the rotary engine, which is now almost finished.


❶❷❸❹❺

❻❼

Headlight frame AHeadlight frame BHeadlight unitHeadlight lensCam mount plate

Type A screws (2.3 x 4 mm) x6Type B screws (2.3 x 8 mm) x6

❻

❼

Attach the headlight unit to part A of the frame. The pieces only fit together in one way.

The right headlight assembled correctly.

Attach the piece you have just assembled to part B of the headlight frame, as shown in the photo.

Clean the headlight unit with a cloth so as not to leave any fingerprints.

Attach the right headlight to the front end of the body.

Insert and tighten two type A screws in the circled holes.

Step

1Step

2

COSMO SPORT COSMO SPORT

The right headlight – 1 The right headlight – 2

Check which way the lens should face, as you did in

stage 33, and then attach it to the headlight unit.

❻

❷❶

❸

❺

❻❹ ❼

❶❸ ❷

❹

LIST OF PIECES

Stage 34Pack 05

77

Step

4 Installing the cam – 2

Step

3 Installing the cam – 1 Attach the cam (no. 6 in stage 33) to its mount plate, as shown in the photo.

Secure the pieces with three type A screws.

Place the crank handle adapter (no. 3 in stage 31) on the hole in the middle of the rotor housing, with the pieces facing the same way as those in the photo.

Position the pieces as shown in the photo and place the intermediate housing on the rotor housing.

Secure the pieces with four type B screws.

Insert the cam unit into the hole in the rotor housing, by aligning the shapes of the pieces.

Secure the pieces with a type B screw. Don’t tighten it completely; you will be adjusting the cam in a later stage.

This is the result of this easy assembly session.

Keep everything you have done in a safe place with the

other pieces.

The next stage

❼

❼

❻

❺ ❸ Stage 31❻ Stage 33

ROTARY ENGINE

ROTARY ENGINE

FINAL RESULT

Stage 34Pack 05

78

VACUUM PUMP

TOOLS NEEDED• Cross screwdriver no. 1• Instant glue

• Tweezers (supplied with this stage)• Scissors

ROTOR HOUSING

THE VACUUM PUMP35

In this stage you will add the vacuum pump and water outlet hose to the engine of your 1:8 scale model. Follow the instructions and explanatory photographs carefully.


❶❷❸❹❺

Vacuum pumpWater outlet hoseRotor housing part UScrews (2.3 x 6 mm) x6Tweezers

Temporarily remove the second washer fluid reservoir.

Temporarily pull the upper hose out of the radiator, being very

careful not to damage the pieces.

Pick up the water outlet hose with the tweezers you received with this stage.

Insert the water outlet hose into the

hole indicated in the photo.

Step

1

COSMO SPORT

The water outlet hose – 1

❷❶ ❸

❺

❹

SECOND WASHER FLUID RESERVOIR

WATER OUTLET HOSE MOUNT HOLE

❷

❺

LIST OF PIECES

UPPER HOSE

Stage 35Pack 05

79

Step

2

Step

3

COSMO SPORT

COSMO SPORT

The water outlet hose – 2

The vacuum pump – 1

Insert the linchpin that is halfway along the water outlet hose into the hole in the car body, indicated in the photo.

Detach the two flexible hoses on the carburettor from the distributors. Insert the linchpin on the vacuum pump into the hole circled in the photo.

Slide the shorter hose on the carburettor onto the vacuum pump, as shown in the photo.

Attach the vacuum pump to the engine unit with a drop of glue.

Reposition the second reservoir and reattach the radiator hose to it. Put the end of the upper hose back into the radiator and apply a small amount of glue to secure the pieces.

Apply a little glue to the end of the radiator hose that goes

into the second reservoir.

❷

❶

FLEXIBLE HOSES ON THE CARBURETTOR

Stage 35Pack 05

80

Step

4 The vacuum pump – 2

Step

5

COSMO SPORT


Cut the flexible hose on the vacuum pump shown in the photo, in exactly the same place that is indicated (just in front of the oil filler tube).

Slide the hose you just shortened onto the linchpin on the oil filler tube.

Slide the other end of the hose on the vacuum pump onto the linchpin on the carburettor, as shown in the photo.

Slide the shorter hose on the vacuum pump onto the linchpin on distributor B, as shown in the photo.

Check that you have joined the hose

to the distributor correctly.

COSMO SPORT

❶

❶

If it is difficult to slide the hoses onto the linchpins, you can use the end of the tweezers to slightly widen the holes in the ends of the hoses.

Widen the hoses with tweezers

❶

Stage 35Pack 05

81

Step

7 The rotor housingAttach part U to the rotor housing, as shown in the photo.

Secure the pieces with five of the screws that came with this stage.

Insert the two spark plugs into the corresponding holes, as shown in the photo.

This is the result of this satisfying assembly

session. Keep everything in a safe place.

Insert the shortest end of the T-shaped hose on the carburettor into the hole in distributor A, from where you removed it in step 3.

Insert the other end of the hose into the hole in the vacuum pump,

circled in the photo.

The next stage

Step

6

COSMO SPORT


❸

❶

ROTARY ENGINE

FINAL RESULT

Stage 35Pack 05

82

INDICATOR

TOOLS NEEDED• Cross screwdriver no. 0• Instant glue

• Tweezers • Flat file

DOWELS

THE INDICATORS – R 36

In this stage you will assemble the right indicator. Handle the pieces extremely carefully so as not to damage them.


❶❷❸❹❺

❻❼❽❾❿

Fuse box mount bracketIndicator unitIndicator lensFuel hoses x2Water hose

Fuse box AFuse box BWire grommet AWire grommet BScrews (1.7 x 4 mm) x2

Attach the LED lights to the indicator unit.

Temporarily remove the washer fluid reservoir.

Pass both hoses through the wire grommets that are already on the car body, as shown in the photo. Slide the other ends of the hoses onto the linchpins circled in the photo.

Slide both of the fuel hoses onto the linchpins

circled in the photo.

Reattach the washer fluid reservoir. You can secure the

piece with a drop of glue.

Secure the pieces with one of the screws

received with this stage.

Attach the indicator unit to the nose (assembled in Pack 1), as shown in the photo. Now attach the indicator lens.

If you have difficulty joining the pieces, lightly file the edge of the indicator unit.

Step

1

COSMO SPORT

The indicatorStep

2

COSMO SPORT

The fuel hoses

LED lightsDowels x3

⓫⓬

❷

❷

❹

❹

⓫

WASHER FLUID RESERVOIR

WIRE GROMMETS

❶

❷

❸

❺

❻ ❽❿

❾

❹

⓫

❼

⓬

❸

Be careful not to damage the pieces!

LIST OF PIECES

Stage 36Pack 05

83

Step

3

COSMO SPORT

The fuse boxStep

4

COSMO SPORT

The water hoses

Step

5 The dowels

Attach the fuse box mount bracket to the car body, as shown in the photo.

Join the two parts of the fuse box, as shown in the photo. Apply a small amount of glue to secure the pieces.

Slide the water hose you received with this stage onto the linchpin on the carburettor, circled in the photo.

Attach the two wire grommets to the right edge of the car body, exactly as shown in the photo.

Slide the other end of the hose onto the linchpin circled in the photo.

Pass the water outlet hose (partly installed in stage 35) through the wire grommets and insert the end into the hole circled in the photo.

Attach the fuse box to its mount bracket, as shown in the photo.

Insert one of the dowels into the hole indicated in the photo.

Insert the remaining dowels into the holes indicated in the photo. You will secure the

pieces in one of the next stages; be careful not to lose them.

You have now finished this satisfying assembly session. Keep everything in a safe place with

the rest of the pieces.

The next stage

❻ ❼

❽

❾

⓬

WATER OUTLET HOSE

❶

❺❺

❻❼

ROTARY ENGINE

FINAL RESULT

Stage 36Pack 05

84

FUEL FILTER

TOOLS NEEDED• Cross screwdrivers no. 0 and no. 1• Instant glue

• Tweezers • Flat file

THE FUEL FILTER37

In this stage you will assemble the left indicator and the fuel filter. Handle the

pieces carefully so as not to damage them.


❶❷❸❹❺

⓫⓬⓭⓮

❻❼❽❾❿

LED lightsFront plate AFront plate BFuel filterBrake booster unit

Fuse box BType A screws (1.7 x 4 mm) x2Type B screws (2.3 x 4 mm) x3Transparent panel

Cap detailBrake booster capIndicator unitIndicator lensFuse box A

⓬

⓭

Attach the LED lights to the indicator unit.

Secure the pieces with a type A screw.

Attach the indicator unit to the nose, as shown in

the photo.

Step

1

COSMO SPORT

The indicators – 1

⓬

❶

❽

❷

❶

❸❺

❽❿

❾⓫

❹

⓮

⓬ ⓭

❼TRANSPARENT PANEL ❻

LIST OF PIECES

Be careful not to damage the pieces!

Stage 37Pack 05

85

Step

2

COSMO SPORT

The indicators – 2

Step

4

COSMO SPORT

The fuel filter – 2

Step

3

COSMO SPORT

The fuel filter – 1If you have difficulty joining the pieces, lightly file the edge of the indicator unit.

Attach the fuel filter to the front plate B, as shown in the photo.

Press until the pieces click

into place.

Position the indicator lens as

shown in the photo.

Make sure the two indicators are aligned. If you like, you can secure them with a drop of glue.

Attach the front plate B to the left side of the front end of the body, as shown in the photo.

Now install the front plate A on the right side of the front end of the body.

Secure the pieces with another type B screw.Secure the pieces with a type B screw.

⓭

⓭

❾ ❹ ❸

❸

❷

❽

Stage 37Pack 05

86

Step

5

COSMO SPORT

The fuse box

Step

6

COSMO SPORT

The brake booster – 1Attach the detail to the centre of the brake booster cap.

Attach the cap to the brake booster unit,

as shown in the photo.

Insert the brake booster into the hole in the front end of the body, as shown in the photo.

Attach the fuse box to its bracket, next to the one you installed in stage 36, as shown in the photo.

⓫ ❿

❻❼

❺ ❻❼

⓫ ❿

Join the two parts of the fuse box, as shown in the photo. Apply a small amount of glue to secure the pieces.

Stage 37Pack 05

87

Step

7

COSMO SPORT

The brake booster – 2

Step

8 The transparent panel

Make sure the panel fits perfectly onto the rest of the model of the rotary

engine. You will secure the pieces in a later stage.

Temporarily attach the transparent panel to the housing.

This is the result of this satisfying assembly session.

Keep everything you have done in a safe place with the

other pieces.

The next stage

Insert the shaped end of the right hose on the brake booster into the hole circled in the photo.

Insert the end of the other hose into the circled hole.

This is what the brake booster hoses look like after having been attached correctly.

⓮

ROTARY ENGINE

FINAL RESULT

Stage 37Pack 05

88

AIR FILTER

TOOLS NEEDED• Cross screwdriver no. 1• Sandpaper (400 grit))

COG

THE AIR FILTER38

In this stage you will add an important element to the engine block of the 1:8

scale model: the air filter. As always, handle any delicate components carefully.


❶❷❸❹❺

❻Air filter unitAir filter coverHooks x3FilterScrews (2.3 x 4 mm) x2

Cog

Place the filter inside the air filter unit, aligning the interlocking elements indicated in the photo.

Attach the air filter unit to the engine block, using the elements indicated in the photo.

Attach the cover to the air filter unit, aligning

the interlocking elements indicated in

the photo.

Secure the pieces with one of the provided

screws.

Press until the pieces click into place.

Step

1

COSMO SPORT

The air filter – 1

❷❶

❸ ❺

❻

❹

❶ ❹

❷

LIST OF PIECES

Stage 38Pack 05

89

Step

2

COSMO SPORT

The air filter – 2

Step

4 The cog – 2

Step

3 The cog – 1Look carefully at the back of the hooks. The printed numbers will help you attach them in the right order.

Attach the cog to the transparent panel from stage 37. Position the pieces as shown in the photo.

Now attach hook "2".

Holding the panel in place, turn the knob on the back of the housing to make sure it functions correctly.

Attach hook "1", as shown in the photo.

Attach the panel to the rotor housing.

Finally, attach hook "3", as shown in the

photo.

Remove the transparent panel and put the cog on the cam, as shown in the photo.

If the cog doesn’t turn easily, you can lightly sand the inside with sandpaper.

If needed, you can also sand

the outer edge, as shown in the

photo.

Make sure the cog on the cam turns smoothly.

This is the result of this easy assembly session. Keep

everything in a safe place.

The next stage

⓮ Stage 37

"1"

"2"

1 2 3

❻

❻"3"

❸

ROTARY ENGINE

ROTARY ENGINE

FINAL RESULT

Stage 38Pack 05

90

Step

1 The differential

DIFFERENTIAL


RECOMMENDED TOOLS• Spanner that came with stage 26

BOLT

THE DIFFERENTIAL39

In this stage you will assemble the differential of the 1:8 scale model and install a few spacers, the rotor and the transparent panel on the 1:2 scale model.


❶❷❸❹❺

❻❼❽❾❿

Differential gearbox ADifferential gearbox BYoke RYoke LPinion

CrownScrews (2.3 x 4 mm) x4Spacer ASpacer BBolts x5

Join the yoke L and the crown, with the pieces facing the same way as those in the photo.

With the pieces facing the same way as those in the photo, place the piece you just assembled in part A of the differential box.

Install the pinion in the position indicated

in the photo.

Complete the differential box with part B and secure the pieces with three of the type A screws that came with this stage.

Attach the yoke R to the other end of the crown.

COSMO SPORT

Double-sided tape⓫

❻

❶

❸❹❻

❹❻ ❸

❷

❺

❷❶

❸

❺

❻

❽

❿

❾

⓫

❹

❼

LIST OF PIECES

Stage 39Pack 05

91

Step

2 The spacers – 1Step

3 The spacers – 2

Step

4 The transparent panel and the bolts

Put the spacer A onto the housing.

This is the result of this satisfying assembly session.

Keep all the pieces in a safe place.

Remove the circled screw and take the cam out of the housing.

Now attach the transparent panel.

Get the rotor and install it on the cam, with the pieces facing the same way as those in the photo.Stick the spacer B

inside the housing, as shown in the photo.

Tighten the bolt with the spanner you received with stage 26. Don’t tighten it completely.

Put the cam back and secure with the screw you removed

previously.

Repeat with the other four bolts.

Stick four strips of double-sided tape onto the spacer

B, as shown in the photo.

Insert a bolt into the circled hole.

The next stage

❾ ⓫

❽ROTARY ENGINE

ROTARY ENGINE ROTARY ENGINE

FINAL RESULT

Stage 39Pack 05

92

DRIVESHAFT

TOOLS NEEDED• Cross screwdrivers no. 1 and no. 2• AAA batteries x2

RECOMMENDED TOOLS• Tweezers

CRANK HANDLE

THE DRIVESHAFT40

In this session you will attach the driveshaft to the differential box; you will also

finish assembling your 1:2 scale model of the rotary engine.


❶❷❸❹❺

❻❼❽❾❿

DriveshaftInner yokes x2Outer yokes x2Adaptors x4Slip yokes x2

Type A screws (2.3 x 4 mm) x10Type B screws (2.3 x 6 mm) x9LinchpinCrank handleScrews C (3 x 6 mm) x2

❻

❼

Look at the photo carefully to familiarise yourself with the assembly sequence.

Secure the pieces with another two type A screws. Don’t tighten the screws completely.

Check that the yoke moves without any difficulty.

Attach an adapter to one

of the outer yokes, as

shown in the photo.

Position the pieces as shown in the photo and

attach the unit to the differential.

Step

1

COSMO SPORT

The universal joints – 1

Secure the pieces with due type A screws. Don’t tighten the screws completely.

Rubber grip⓫

❻

❺ ❹ ❷

❸ ❸❹

❸ ❹

❹

❷

❶

❸

❺

❻ ❽

❿

❾

⓫

❹

❼

LIST OF PIECES

Stage 40Pack 05

93

Step

2

Step

3

COSMO SPORT

COSMO SPORT



❼

Attach an adapter to one of the inner yokes, as shown in the photo.

Secure the pieces with a type B screw.

Repeat on the other side, using another type B screw. The adaptor must be at the centre of the yoke.

Attach the unit to one of the slip yokes.

Secure the pieces with two type B screws, adjusting them so that the adaptor is at the centre of the slip yoke.

Insert the inner yoke of the part you just assembled into the outer yoke you installed on the differential.

The first universal joint assembled correctly.

Repeat the previous steps to assemble and attach the second universal joint on the other side of the differential.

The shape of the inner yoke means that the pieces can only be joined

in one way.

❹

❸

❸

❹

❺

❺

❷❹

❷❹❺

❷❹❺

❷❹

❷

Stage 40Pack 05

94

Step

4

COSMO SPORT

The driveshaft

Step

6 Test

Step

5 The crank handle

Insert two AAA batteries into the battery holder and turn the crank handle in the direction indicated in the photo.

Check that rotor turns easily and that the LED

lights on the spark plugs turn on in the order shown in the photo

(bottom one first). You have now finished your 1:2 scale model of the

rotary engine!

Slide the rubber grip onto the crank handle, as shown in the photo.

Secure the pieces with a type C screw.

Put the crank handle onto the linchpin on the back of the rotary engine.

This is the result of this satisfying assembly session. You have now finished your

1:2 scale rotary engine. In the next stage we will give you a

few maintenance tips.

Secure the pieces with a type A screw.

Attach the driveshaft to the differential.

The next stage

❻

❶

❾ ⓫

ROTARY ENGINE

ROTARY ENGINE

FINAL RESULT

Stage 40Pack 05

95

❷❶

❸

❹

SEAT CUSHION

TOOLS NEEDED• Cross screwdriver no. 1• Sellotape• Pliers (stage 17)

• Spanner (stage 26)• Scissors

THE ROTARY ENGINE41

In this stage we will give you a few tuning and maintenance tips for your 1:2

scale rotary engine, which you finished assembling in the previous stage.

❶❷❸❹

Seat cushionHingeLeverScrews (1.7 x 5 mm) x3• Model car oil

Attach the lever to the bottom of the seat cushion, positioning the pieces as shown in the photo. You will adjust the distance between the seat and the platform in a later stage.

You have finished working on the seat for now. Keep the pieces in a safe place.

Step

1

COSMO SPORT

The seat cushion

❶

❸

STRUMENTI CONSIGLIATI

LIST OF PIECES

Stage 41Pack 05

96

Dismantling – 1

Dismantling – 2

Maintenance and tuning tips

Remove the five bolts, being careful not to damage the transparent panel.

Remove the screw in the cam and take the later out of its housing.

Remove the panel, the spacer, the rotor and the three dowels.

Also remove the screws from the holes circled in the photo.

Also remove the spark plugs, the cog and the crank handle.

The two parts of the housing separated correctly.

If your model is already working correctly, you can ignore the following pages. If, on the other hand, you feel it is necessary to adjust some moving parts, the LED lights, a few loose screws, etc., carefully follow the steps below.

Stage 41Pack 05

97

The switches1

To function properly, the two switch arms must be at the same height when the crank handle adapter is in the position shown in the photo. In this example photo, the left switch arm is slightly lower than the right one.

Being very careful not to break the arm, adjust it with a pair of pliers until it is at the same height as the other one.

Reinsert the cam and move it around inside the housing to see if it is tight enough.

Also check the movement of the crank handle adapter. If the LED lights on your model aren’t functioning correctly, it could be that the adapter is too loose.

If you think it’s necessary, you can increase the thickness of the

adapter with a little bit of sellotape. Be careful not to create any bumps

as you apply the tape.

In this example photo, we have increased its thickness by applying a few strips of sellotape.

If the cam is too loose inside the housing, you can adjust its thickness with a little bit of sellotape.

The cam and the adaptor

2

Stage 41Pack 05

98

If the rotor isn’t turning smoothly, we suggest you apply a thin layer of oil.

Apply a thin layer of model car oil on the outer surface of the rotor and in the groove inside, as shown in the photo.

If you like, you can also lubricate

the inside edge of the housing.

In this assembly session you learnt how to tune the various parts of your 1:2 scale model and you started working on the first seat of the 1:8 scale model.

The next stage

Reassembling and closing

Turn the crank handle to check that everything is

functioning correctly.

Check that the LED lights on the spark plugs turn on in the right order (bottom one first).

You can now put all the pieces back together and close the model.

The rotor3

FINAL RESULTOn stage 46…

Stage 41Pack 05

99

pack 05 - us website · 2021. 2. 8. · 35 the vacuum pump in this stage you will add the vacuum...

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