Chassis Folding Instructions

The initial keys to proper folds of the chassis tabs are:
  1. Use a NEW hinge and vise grips or GOOD bench vise for clamping.
  2. Ensure the edge of the clamping device is not less than 1/64" or
       more than 1/32" from the fold line and the clamp edge is parallel.
  3. Bend once to achieve as close to a 90 degree bend as possible.
  4. The bending motion should be slow and steady to allow the narrow
       aluminum attachment points to stretch and form. It is suggested to
       do this at room temp.

The first bend to make is the motor tab in the rear chassis half.
Note the position of the motor mounting holes!. Position the chassis so this is the view you see.

Set the fold line spacing in the clamp and gently tighten the clamp. From the back, use your thumb to push the motor tab toward you to a 90 degree angle. The GM 9330 motor will require a slight over bend - this can be accomplished later when aligning the motor to the crown / axle.

Position the chassis in the clamp to bend one of the rear axle bosses. These bosses must
be bent the same direction as the motor tab. Again, use your thumb to make the bend pushing on the chassis body as close to the fold line as possible. Compare the boss fold to the edge of the motor mount tab for proper amount of bend.

Position the front chassis in the clamping device to bend the side rails.
This one doesn't have a top or bottom. The side rails can be removed if so desired.
Use your thumbs to make the bends.

Position the front chassis in the clamping device to bend the front axle bosses.
These bosses are bent the same direction as the side rails. Use your thumbs
to make the bends.

Once the folds are made, gently pry open the rear axle boss ears just enough to allow easy entry of the bushing. Clean the bushings and the axle bosses with alcohol (rubbing alcohol that is) soaked into a clean cloth and allow it to dry. Use a toothpick or similar applicator to apply a thin coat of Super Glue to the outside of the axle boss. Carefully insert the bushing into the axle boss and hold it flat against the boss. Use small pliers to gently squeeze the ears closed to clamp the bushing. Repeat for the opposite side. While the glue is drying adjust the alignment of the front axle bosses.

To adjust the axle boss alignment, insert an axle into one hole. Hold the chassis vertically and watch how the axle lines up with the opposite hole. Gently, and ever so slightly, bend the boss the direction needed to get the axle aligned to the opposite hole. Once the alignment is correct, remove the axle and insert it from the opposite direction and make the same checks and adjustments. Once everything is aligned the axle should slide easily through the holes and rotate smoothly.

To help strengthen the fold joints, two part epoxy can be used to fill in the fold gaps on the outside of the fold apex. A small epoxy fillet can also be applied to the inside of the fold apex for further strength. Be certain the areas to be filled are clean. The strengthening really only needs done on the rear half. Once the entire assembly and length adjustment is complete and the gear mesh set, be certain to lube the axle rotation points. I use 3-in-1 oil and apply a drop at a time with a toothpick.

Traction magnets can be installed in the four holes, in the pocket under the motor, or on the flat area of the chassis between the motor and the crown gear pocket.

Here's a couple links for further instructions and insight on this product:
        http://homepage.mac.com/pmarchand/Ranch_Design_Chassis_Kit.htm (Thanks Philippe!)
        http://www.freewebs.com/hungryhill/ranchdesign.htm  (Thanks Stranger!)


If you have problems or questions, please feel free to send an email to liberty@ranch-design.com

Enjoy your new slot car!