5 x 1.

8mm

ASSEMBLY GUIDE
B E T A E D I T I O N 1 . 0
DISCLAIMER

ASSEMBLY GUIDE
B E T A E D I T I O N 1 . 0

FOR EVALUATION PURPOSES ONLY

Whilst every effort has been made to ensure the information in the following pages is
accurate; this beta version of Assembly Guide is published to gain feedback on the layout
and principle only.

Please address any comments to: [email protected]

21 July 2016

i
ASSEMBLY GUIDE EDITION 1_BETA
HINTS & TIPS

When using a torque wrench, listen/ A ‘nyloc’ nut is one with a nylon insert that gets cut by the bolt
feel the click and then stop. It does thread, making it resistant to unwinding itself. This means that
not need to be any tighter and you they should not be repeatedly re-used.
might actually weaken the fixing by Chris B
‘over-torquing’ it. Always wind your
torque wrench setting back to free
when you’ve finished with it. When using a spanner, always use the ring
John K 1Nm of torque end wherever possible. The open end is
equals 0.736lbft. really only for those times that access is too
Mick F limited for a ring spanner or socket.
Mick A

A ‘spring washer’ has a split in it and squashes up

closed when a fixing is tightened. It is usually used A ‘caphead bolt’ has a circular head
under a bolt head to help resist it coming undone. with a hexagonal drive inside it. It is
John S tightened with an allen key or hex
drive socket. Capheads are useful
where there is limited space around
the head for a spanner or socket.
They look nice too!
John K

4
ASSEMBLY GUIDE EDITION 1_BETA
HINTS & TIPS

You can tell if you have ‘wide track suspension’ car by looking Generally, metric
at the front dampers. Wide track has a 25mm long hexagonal Nyloc nuts have a
spacer between the top spring retainer and the mounting bush. blue nylon insert and
Matt T imperial ones a white
nylon insert.
Grant P
Thread lock is
used to stop
something
coming undone, Left and right are
A bolt size is described by its diameter
but it only as viewed from the
(eg M10=10mm) by the length not including
needs a little driver’s seat.
the head (eg 65mm).
drop on the Harrison P
James A
thread to be
effective.
Jamie A Teabag, boiling
water, then the
milk, in that order.
Simon L

1
ASSEMBLY GUIDE EDITION 1_BETA
 KEY
S Y M B O L S

1 Item number Advice from factory

professionals
AA
AJ Fixing item
AM

S Pack / R Pack
specific instructions

35 Nm Required torque (where applicable)

mm

S3
S3 / S5 chassis specific instructions
S5

x2 Repeat on both sides

F I X I N G S

A
SERIAL
44
Pack
NUMBER

A
SERIAL
44 PACK NUMBER
Pack
NUMBER

PACK NUMBER 30F015B

30F015B

FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options
BASIC PART
ITEM QTY USED ON ILLUSTRATION BASIC PART
DESCRIPTION NUMBER ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER

Bolt M12 x 100 Lower wishbone

1 AA BM12X100 2
Grade 10.9 rear
Bolt M12 x 100 Lower wishbone
1 AA BM12X100 2
Grade 10.9 rear
Bolt M12 x 65 Lower wishbone
2 AB BM12X65 2
Grade 10.9 front

Bolt M12 x 65 Lower wishbone

2 AB BM12X65 2
Bolt M10 x 65 Upper wishbone
Grade 10.9 front
3 AC BM10X65 2
Grade 10.9 rear

Upper wishbone Bolt M10 x 65 Upper wishbone

4 AD
Bolt M10 x 60
BM10X60 2 3 AC BM10X65 2
Grade 10.9 front Grade 10.9 rear

Anti-roll bar
x4 (Indicates number of each fixing required)
Bolt M8 x 40
5 AE BM8X40 4
Grade 10.9 mounting brackets Bolt M10 x 60 Upper wishbone
4 AD 2 BM10X60
Grade 10.9 front
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint
Bolt M8 x 40 Anti-roll bar
5 AE BM8X40 4
Grade 10.9 mounting brackets
Lower wishbone
7 AG Nyloc Nut M12 NMYF12 2
rear

Temporary use to
Plain Nut M14
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint

Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone Lower wishbone
Chamfered 7 AG Nyloc Nut M12 NMYF12 2
rear
Plain Washer
Anti-roll bar
10 AK 4

(Greyed out4 area indicates fixings are not

M8 WPHM8
Heavy duty mounting brackets
8 AH Nyloc Nut M10 Upper wishbone
NMYF10

required for current step)

Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty

Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered

Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets

2
ASSEMBLY GUIDE EDITION
Plain Washer 1_BETA
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty

Drawings are for illustrative purposes only and are not to scale. Page 1 of 2
KEY
T O O L S

LO
Allen key Pop rivet gun Socket wrench Thread lock

CT
Grease

IT
E
Socket wrench
+ Assistance Hammer Power adhesive
(allen)
Torque wrench

Pozidrive
Axle stand Heat gun Spirit level Trolley jack
screwdriver

Pozidrive
Combination
Junior hacksaw screwdriver Spray lube WD40
spanner
(stubby)

Copper slip S
Latex gloves UAL
Reading manual Stanley knife Tool
VE
MAN
tex

GLO
La

Drill Long nose pliers Scissors Sticky tape Tool

Drill bit Mallet Side cutters R

Super glue Tool
PE E
S UGLU

Flat dzuz
Marker pen Silicon Tap wrench Tool
screwdriver

Flat head
Muscle Silicon gun Tape measure Tool
screwdriver

3
ASSEMBLY GUIDE EDITION 1_BETA
LETS GET READY
P A R T S T O O L S

x3

F I X I N G S T I P S

When deciding how high your axle stands should be (the higher
the better for working on), don’t forget that a complete car will
need to come down off them, so make sure your trolley jack can
reach and lift the height you set them too!
Mick F
Some tape or foam on the top of the axle
stands will stop them scratching the chassis.
Matt T

4
ASSEMBLY GUIDE EDITION 1_BETA
LETS GET READY

5
ASSEMBLY GUIDE EDITION 1_BETA
START WITH THE SUSPENSION WISHBONES
P A R T S T O O L S

1 Lower wishbone
17mm
19mm
2 Upper wishbone

17mm
3 Wishbone bush sleeve
19mm

F I X I N G S T I P S

A A
SERIAL
44 SERIAL
44
Pack Pack For now, only tighten the nuts/bolts lightly and then torque them
NUMBER NUMBER

PACK NUMBER PACK NUMBER

30F015B 30F015B

FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) up when the car is finished and on the ground. This sets the bushes
ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION
correctly and ensures the best handling.
DESCRIPTION NUMBER DESCRIPTION NUMBER

Harrison P
1 AA
Bolt M12 x 100
Grade 10.9
BM12X100 2
Lower wishbone
rear x2 12 AM
Spring Washer
M12
WSHM12 2
Lower wishbone
front x2
Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front x2 13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount

3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear x2 14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe

4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front x2 15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay

Front brake, upright

Bolt M8 x 40 Anti-roll bar Nyloc Nut ½"
5 AE BM8X40 4 16 AS NFYF1/2 2 mounting (std track
Grade 10.9 mounting brackets Full height
ONLY)

Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint

7 AG Nyloc Nut M12 NMYF12 2

Lower wishbone
rear x2
8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone
x4
x14
Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered

Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets

Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty

Drawings are for illustrative purposes only and are not to scale. Page 1 of 2

6
ASSEMBLY GUIDE EDITION 1_BETA
 START WITH THE SUSPENSION WISHBONES

35
AD
35 35
AC
35
mm mm
34Nm mm mm
34Nm
AH AH

AA
35
mm
AJ
35
mm
81Nm

AG

x2
AB
35
mm
AJ
35
mm
81Nm

AM

7
ASSEMBLY GUIDE EDITION 1_BETA
NOW FOR THE STEERING RACK
P A R T S T O O L S

1 Steering rack
10mm
13mm
2 Rack clamps

3 Column universal joint 5mm

4 Track rod end

13mm
22mm
5 IVA cover ¾"

F I X I N G S T I P S

B
SERIAL
55
Pack
NUMBER

PACK NUMBER
30S003B
Finding the right IVA cover isn’t obvious
STEERING DeDION CARS (METRIC) because it is effectively a long cap. To use it,
ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION
you cut the closed end off.
DESCRIPTION NUMBER

Jamie A
x4
Caphead Bolt
1 BA M6 x 70 BMCH6X70 4 Rack clamps
DIN 912

2 BB Bolt ¼" x 1½" BF1/4X1.1/2 2 Column clamp

3 BC
Bolt M8 x 35
Grade 8.8
BM8X35 2
Column to rack
universal joint x2
Nyloc Nut ½"
4 BD Half height
NFYH1/2 1 Steering wheel boss

5 BE Plain Nut ½" NFPF1/2 2 Track rod lock nut

x2
Plain Nut ⁷⁄₁₆" Column clamp
6 BF NFPFH7/16 1
Half height grubscrew locknut

7 BG Nyloc Nut M8 NMYF8 2

Column to rack
universal joint x2
8 BH Nyloc Nut M6 NMYF6 4
Steering rack
clamps x4
Plain Washer
9 BJ ½" x 1⅛" WPH1/2 1 Steering wheel boss
Chamfered

x4
Plain Washer
Rack clamps and
10 BK ¼" WPH1/4 6
Heavy duty column clamp

Spring Washer ¼
11 BL Heavy duty
WSH1/4 2 Column clamp

Drawings are for illustrative purposes only and are not to scale. Page 1 of 1

8
ASSEMBLY GUIDE EDITION 1_BETA
 NOW FOR THE STEERING RACK

BC
35 35 20Nm
mm mm
BG

BA 5
35
mm
BH
35
mm
11Nm

BK 2 1

BE

9
ASSEMBLY GUIDE EDITION 1_BETA
AND THEN THE DAMPERS
P A R T S T O O L S

1 Spring / damper
6mm

2 Lower damper eyelet

3 Upper damper eyelet 6mm

F I X I N G S T I P S

A A
SERIAL
44 SERIAL
44
Pack Pack
NUMBER NUMBER

PACK NUMBER
30F015B
PACK NUMBER
30F015B Put the top of the
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) damper on first.
This pack may include extra fasteners to cover different options This pack may include extra fasteners to cover different options

ITEM
BASIC PART
QTY USED ON ILLUSTRATION ITEM
BASIC PART
QTY USED ON ILLUSTRATION
Grant P
DESCRIPTION NUMBER DESCRIPTION NUMBER

Bolt M12 x 100 Lower wishbone Spring Washer Lower wishbone

The bottom can
be a tight fit!
1 AA BM12X100 2 12 AM WSHM12 2
Grade 10.9 rear M12 front

Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front
13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount
x2 Mick F
Bolt M10 x 65 Upper wishbone Washer ⅜"
3 AC BM10X65 2 14 AP WSS3/8 2 Brake pipe
Grade 10.9 rear Shake-proof

Bolt M10 x 60 Upper wishbone Nyloc Nut ½"

4 AD BM10X60 2 15 AR NFYH1/2 2 Wing stay
Grade 10.9 front Half height

Front brake, upright

Bolt M8 x 40 Anti-roll bar Nyloc Nut ½"
5 AE BM8X40 4 16 AS NFYF1/2 2 mounting (std track
Grade 10.9 mounting brackets Full height
ONLY)

Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint

7 AG Nyloc Nut M12 NMYF12 2

Lower wishbone
Other fixings provided in chassis
& wishbone.
rear

8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone

Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered

Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets

Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty

Drawings are for illustrative purposes only and are not to scale. Page 1 of 2

10
ASSEMBLY GUIDE EDITION 1_BETA
AND THEN THE DAMPERS

35
mm
35
AN
mm
20Nm 3

�
7

1
�
35 35 20Nm
mm mm

11
ASSEMBLY GUIDE EDITION 1_BETA
IT’S TIME FOR THE WINGSTAYS
P A R T S T O O L S

1 Wingstay
22mm
¾"
2 Front brake & upright assembly

F I X I N G S T I P S

A A
SERIAL
44 SERIAL
44
Pack Pack The drilled hole is for the side repeater earth that we’ll fit later. It’s easier
NUMBER NUMBER

PACK NUMBER PACK NUMBER

30F015B 30F015B

FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC) to drill from the top and down through both sides of the tube, rather
ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION ITEM
BASIC
This pack may include extra fasteners to cover different options
PART
QTY USED ON ILLUSTRATION
than through one side from the bottom (where the earth will be fixed).
DESCRIPTION NUMBER DESCRIPTION NUMBER

Tiago O
1 AA
Bolt M12 x 100
Grade 10.9
BM12X100 2
Lower wishbone
rear
12 AM
Spring Washer
M12
WSHM12 2
Lower wishbone
front Use the plain nut to
2 AB
Bolt M12 x 65
BM12X65 2
Lower wishbone
13 AN
Spring Washer
WSHM8 6
Anti-roll bar
mounting brackets & pull the top ball joint
front upper damper

home before using a

Grade 10.9 M8

mount

3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe Some of the fixings required and shown on the nyloc, otherwise the
drawings, such as the ball joint nut, are already on thread will spin.
4 AD
Bolt M10 x 60
Grade 10.9
BM10X60 2
Upper wishbone
front
15 AR Nyloc Nut ½"
Half height
NFYH1/2 2 Wing stay
x2 the part and not in the fixing pack. Chris N
Anthony L
Front brake, upright
5 AE
Bolt M8 x 40
Grade 10.9
BM8X40 4
Anti-roll bar
mounting brackets
16 AS Nyloc Nut ½"
Full height
NFYF1/2 2 mounting (std track
ONLY) x2
Drawings are for illustrative purposes only and are not to scale. Page 2 of 2

6 AF
Plain Nut M14
x 1.5 thread
NMPH14 1
Temporary use to
help lock upper
wishbone ball joint
Put the ‘upright’ into the lower wishbone
Lower wishbone
joint then attach the steering before
7 AG 2

tightening the bottom nut. This stops it

Nyloc Nut M12 NMYF12
rear

8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone all swinging around the hitting the side
9 AJ
Plain Washer
M12 WPCM12 18 Lower wishbone
of the chassis.
John S
Chamfered

Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets

Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty

Drawings are for illustrative purposes only and are not to scale. Page 1 of 2

12
ASSEMBLY GUIDE EDITION 1_BETA
IT’S TIME FOR THE WINGSTAYS

1 x1/8”

7
1 x1/8”

AR 2

x2
35 AS
35 54Nm
WIDE
mm mm

TRACK (STANDARD TRACK ONLY)

13
ASSEMBLY GUIDE EDITION 1_BETA
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
P A R T S T O O L S

1 Anti-roll bar
13mm

2 Anti-roll bar bracket

3 Anti-roll bar rubber

4 Anti-roll bar ball

LO
CT
IT
E
5 Anti-roll bar dust cover

F I X I N G S T I P S

A A
SERIAL
44 SERIAL
44
Pack Pack Check that the colour of the mounting
NUMBER NUMBER

PACK NUMBER
30F015B
PACK NUMBER
30F015B Use four small cable ties
FRONT SUSPENSION DeDION CARS (METRIC) FRONT SUSPENSION DeDION CARS (METRIC)
rubbers matches the colour spot on the bar. to secure the dust cover.
BASIC
This pack may include extra fasteners to cover different options
PART BASIC
This pack may include extra fasteners to cover different options
PART
John K Mick F
ITEM QTY USED ON ILLUSTRATION ITEM QTY USED ON ILLUSTRATION
DESCRIPTION NUMBER DESCRIPTION NUMBER

1 AA
Bolt M12 x 100
BM12X100 2
Lower wishbone
12 AM
Spring Washer
WSHM12 2
Lower wishbone Getting the assembled anti-roll bar
fully into both cups on the upper
Grade 10.9 rear M12 front

Anti-roll bar
2 AB
Bolt M12 x 65
Grade 10.9
BM12X65 2
Lower wishbone
front
13 AN
Spring Washer
M8
WSHM8 6
mounting brackets &
upper damper
mount
x4 Grease the balls and wishbone can be a bit of a fight.
3 AC
Bolt M10 x 65
Grade 10.9
BM10X65 2
Upper wishbone
rear
14 AP
Washer ⅜"
Shake-proof
WSS3/8 2 Brake pipe cups generously. It’s made of springy stuff, so don’t
Matt T worry that you are bending it.
Bolt M10 x 60 Upper wishbone Nyloc Nut ½"

Jamie A
4 AD BM10X60 2 15 AR NFYH1/2 2 Wing stay
Grade 10.9 front Half height

Front brake, upright

5 AE
Bolt M8 x 40
Grade 10.9
BM8X40 4
Anti-roll bar
mounting brackets x4 16 AS Nyloc Nut ½"
Full height
NFYF1/2 2 mounting (std track
ONLY)

Drawings are for illustrative purposes only and are not to scale. Page 2 of 2
Temporary use to
Plain Nut M14
6 AF x 1.5 thread
NMPH14 1 help lock upper
wishbone ball joint

Lower wishbone
7 AG Nyloc Nut M12 NMYF12 2
rear

8 AH Nyloc Nut M10 NMYF10 4 Upper wishbone

Plain Washer
9 AJ M12 WPCM12 18 Lower wishbone
Chamfered

x4
Plain Washer
Anti-roll bar
10 AK M8 WPHM8 4
Heavy duty mounting brackets

Plain Washer
11 AL ⅜" x ¾" WPH3/8 2 Brake pipe
Heavy duty

Drawings are for illustrative purposes only and are not to scale. Page 1 of 2

14
ASSEMBLY GUIDE EDITION 1_BETA
LAST PART OF THE FRONT SUSPENSION: CONNECTING THE TWO SIDES TOGETHER
AE
35 35
AK 20Nm
mm mm

AN
4

15
ASSEMBLY GUIDE EDITION 1_BETA