D51 200 Steam Locomotive: STEP BY STEP Stage 29 ™ The smokebox door fittings and headlight Headlight Your parts 60 1 Fitting the handle Hold the handle in place so that it protrudes through the back of the LED (with wires) Headlight lens Required tools door by 3mm, and apply Connector Smokebox door superglue to the ends to Lock handle Tweezers secure it in place. Lever Smokebox door Sidecutters When the glue Terminals × 2 locking bar Instant adhesive is dry, cut off the Handril brackets × 4 Epoxy adhesive protruding ends of the handle. Right handrail Masking tape Insert the handle into the two holes on Left handrail the smokebox door. Door handle Headlight D51 200 Steam Locomotive: STEP BY STEP ™ 2 Fitting the locking bar 3 Fitting the handrails Lift the handrail 5mm Apply epoxy adhesive to both ends of the slightly to expose smokebox door the lower parts of locking bar. the brackets. Apply superglue to these areas and place Screw the handle into the hole in back into position. the lever and then insert the end of the handle into the hole in the centre of the smokebox door. Place two brackets into the holes on the upper right side of the smokebox front plate, and insert the right Apply some handrail through the holes in both. epoxy to the tip of the handle and place the lock Apply a small onto the tip, amount of aligning it with superglue to the Glue the bar between the two one of the handrail where it Follow the same process to fit the 61 projections on either side of the cross struts of passes through the left handrail and brackets into the boiler ring (circled). the handle. brackets, as shown two holes on the upper left side of in the photo. the front plate. 4 Assembling the headlight Assembled parts Place the lens in the headlight and hold in place with masking tape. The power supply will be delivered at a later stage, so these parts won’t be secured until the LED has been tested. Insert the bottom of the headlight into the front plate and Pass the two ends of the secure with glue. LED wire through the hole in the headlight and out through the bottom. Pass the LED wire through the hole at the top of the smokebox front plate. D51 200 Steam Locomotive: STEP BY STEP Stage 30 ™ The handrails, superheater element plate and LED Superheater element plate Your parts 62 1 Fitting the handrails Turn the two nuts onto the brackets to secure to the smokebox, Screws (2 × 4mm) × 2 Required tools ensuring the holes in the brackets are Handle kept aligned. Pivots × 2 Long-nose pliers Superheater header Tweezers Handrail brackets × 4 Phillips screwdriver Repeat this Instant adhesive Nuts × 4 Apply some contact adhesive to the tip process to fit the Superheater element plate Contact adhesive of one of the brackets and insert it into two brackets on the hole on the left side of the smokebox. the right side of Place a nut onto the end of the bracket. the smokebox. Repeat this to fit a second bracket into Make sure the the hole behind the first (circled). Before holes are aligned. securing, align the holes in the brackets. D51 200 Steam Locomotive: STEP BY STEP ™ Fitting the handle and pivots Assembling the superheater element plate 2 Place the pivot with the handle 3 into the circled hole on the Glue the handle right side of the smokebox. Apply some Instant adhesive onto one of the contact adhesive pivots. to the circled hole in the superheater header and place it in the recess in Position the handle facing down the superheater element plate. Apply instant adhesive to the area of the pivot on the Pass the LED wire from the inside of the Place the headlight over the superheater smokebox. second pivot Tighten a 2 x header and through the hole in the hole on 4mm screw into in the top of the superheater the left side of the hole in the element plate. the smokebox plate, securing and glue from the header to it. 63 the inside. 4 Fitting the terminals and connector Assembled parts Terminal Fold in Trim Insert the ends of the two wires into the connector, as shown below, Then fold the two shorter with the red wire Trim the insulation off the end of arms in the middle of the on the left and the black LED wire and place a terminal to hold the wire the black on terminal from Stage 29 next to it. in place. the right. Insert the wire into Red wire, left (+) the terminal, and Fold in fold the two arms over the insulation to hold it in place. Black wire, right (-) Raised side D51 200 Steam Locomotive: STEP BY STEP Stage 31 ™ The boiler 1 Lower boiler half There is an extra hole Your parts 64 1 Preparing the parts Right boiler joint Right boiler joint Required tools Inside Front Lower boiler half Left boiler joint Phillips screwdriver Outside Self-tapping screws × 3 Outside Screws (2 × 4mm) × 30 Inside Arched Holes at the front Place the right boiler joint in front of you, as shown. Identify the outer and Hold the right boiler joint up against the lower boiler half, inner sides. aligning the circled holes, with the back ends of the two parts in line. D51 200 Steam Locomotive: STEP BY STEP ™ 2 Fitting the boiler joints Screw the lower half of the right boiler joint on the inside of the lower boiler half using 2 x 4mm screws, omitting the circled screw hole. Screw the left boiler joint to the lower boiler half. Do not screw Front Hold the left boiler joint on the inside of the lower boiler half, aligning the holes and back ends of both. The lower boiler half should now Front look like the one shown above. 65 Fitting the lower boiler half 3 Tighten a 2 x 4mm screw into Fit the superheater the first hole element plate of the boiler into the back of half, and a self- the smokebox, tapping screw aligning the holes into the second on the plate hole (arrowed), Assembled parts with those of the securing it to the boiler hinge joint element plate. (circled). Turn the smokebox upside down and place the lower boiler half over Tighten a 2 x 4mm screw into the joint, aligning the holes. each of the four holes. Repeat this process for the right side of the boiler. D51 200 Steam Locomotive: STEP BY STEP Stage 32 ™ The boiler 2 Upper boiler half Your parts 66 1 Fitting the handrail brackets Holding the bracket Front in place, tighten a nut Upper boiler half Required tools with some contact adhesive in it onto the Steam pipe end of the bracket. Screws (2 × 4mm) × 20 Phillips screwdriver Self-tapping screws × 3 Contact adhesive Handrail brackets × 6 Place the upper boiler Nuts × 6 half, three handrail Front brackets and three nuts, as shown. Insert the first handrail Fit a further five brackets and bracket into the circled hole nuts to the upper boiler half, in the upper boiler half. aligning the holes. D51 200 Steam Locomotive: STEP BY STEP ™ 2 Fitting the boiler top Front Tighten a self-tapping screw into the second hole from the front of the Repeat this process for the right Place the upper boiler half onto the lower one, Tighten a 2 x 4mm screw into each of the circled upper boiler half. side of the upper boiler half. aligning the holes with the joints. holes on the left side of the boiler half. 67 The steam pipe 3 Assembled parts Although the steam pipe is not fitted at this stage, the photo above shows you where it will be positioned..