Return to the BUILD
“In this stage, you finish building the left rear door, fitting it to your model.”
Materials: Gear 3, Gear 4, and the Window Lever are metal, but the rest of these parts are plastic.
Window Mechanism & Inner Door
Fit the keyed post of the Interior Door Handle to this matching hole of the Left Rear Door Inner Panel:
Secure the Interior Door Handle in place from behind with one (1) EP screw:
Fit the post of the Window Lever through this hole of the Left Rear Door Inner Panel:
Then, fit Gear 3 onto the exposed post of the Window Lever from the other side, and secure it all with one (1) KM screw as shown.
Gear 3 is the one with the D-shaped center hole. This is also your friendly reminder to try using 3-in-One Oil on all screws going into metal:
Finally, fit Gear 4 over this last post of the Left Rear Door Inner Panel, and secure it into place with one (1) UP screw.
I did not get a picture of the UP screw installed, but this is where it goes:
Once these gears were in place, I tested the window mechanism by turning the Window Lever. I found that there were a few spots where the gears seemed to stumble and catch. This was due to some rough teeth on Gear 3 and Gear 4, probably where they were cut from their sprues. I used some sandpaper to smooth these teeth down and reinstalled the gears. Everything is much smoother now!
Retrieve your Left Rear Door Window from Stage 85. Fit the slot of this window over the post on the end of Gear 2, and secure with one (1) UP screw.
If you are not sure which way the window should be fitted, just make sure it matches the shape of the door panel, as shown:
Retrieve your Left Rear Door assembly from Stage 86. Fit this Inner Panel assembly to the inside of the Left Rear Door.
The only real way to fit these parts together is to slide the upper edge of the window underneath these two tabs of the door (circled below), then carefully slide the entire panel/window assembly up into place. There is a groove in the door the windows slides along:
Also, make sure the Hinge is out of the way:
Once fitted, the holes in the door panel should line up with the matching posts of the door:
Secure the upper edge of the Inner Panel to the Left Rear Door with two (2) IP screws:
Secure the lower edge of the Inner Panel to the Left Rear Door with two (2) DM screws:
Push the pins of the two Left Rear Door Inner Skirting parts into these two grooves of the Left Rear Door Inner Panel, as shown.
Both Left Rear Door Inner Skirting parts are identical. Also, the pins of the skirting will only align to the matching holes of the panel one way:
Push the D-shaped post of the Left Rear Door Lock into this matching hole under the Left Rear Door Handle:
Retrieve your Chassis assembly and disconnect the Rear Left Door Switch cable (marked ‘V’):
Retrieve your Body assembly and fit the switch of the Rear Left Door Switch cable into this notch behind the left rear door opening.
The instructions were not very clear here and I ended up installing this switch backwards. I was frustrated with the fitment and even went so far as to sand a notch into the Switch Cover to make it all fit. Then, when the door was installed the switch kept it from closing. Don’t make the same mistake:
Instead, the switch should be installed in this orientation:
I did need to bend the wires of the switch to the side a bit to make it fit a little better:
When the switch is fitted correctly, it should look like this:
Secure the Rear Left Door Switch to the Body Middle Frame with the Switch Cover and two (2) DM screws, as shown.
Make sure the wiring of this switch passes through this notch in the Body (arrow below), as shown. Also, do not over-tighten these screws as the plastic Switch Cover can split quite easily:
To make sure this switch is operating correctly, use a thin tool (like these tweezers) to push the switch lever towards the center of the body. If you can not, you might need to re-orient your switch:
Fit the Left Rear Door Catch into this slot above the Rear Left Door Switch and secure it with one (1) DM screw, as shown:
Carefully turn the Body assembly upside down on a soft cloth. Fit the hinge of the Left Rear Door to this location on the body at the left-side B pillar:
Secure the hinge into place with two (2) UM screws.
There is a small amount of ‘wiggle’ room with these screws if you need to adjust the alignment of the door:
That step concludes this stage. We should be able to open and close this Left Rear Door without any issues:
We have made good progress now building and attaching two of the doors! Work continues along the left side in the next stages.
Stage 89 – Left Rear Window Frame, Window Frame Skirting