ASSEMBLY GUIDE

Assembling the Discovery model is much simpler than it appears.  No tools are needed and only a couple drops of white glue will be used.

The first thing to note is that each of the 11 module groups are numbered, indicating their position in the spine starting from the front of the ship. The Antenna Module group is #7, but carries no identification since it is unique:  it has 4 sides and the top is indicated by the module that the antenna fits onto.

Each of the module groups has a small indentation at the forward end.

The identification number is written in pencil inside the hole of the forward end.  The indentation also indicates 'top' for the module group, so when the module is placed on the spine rod, the indentation should be aligned to be on the top of the spine.  There is drawing included that shows the ship from the right side, as the pilot faces forward, and that can be used to rotate the module groups into the correct position.

There are also 11 spacers.  Each of these go onto the spine rod between each module group.  They should be rotated so that a single fin is pointing upward.

The spine rod itself is painted, but the ends, which fit into the 'neck' at the front end and the engine section at the rear, are left unpainted.  If the ends were painted, it is possible that the paint would bond to the inside of the holes over time and make it difficult to remove.  One thing to note that is not obvious is that the rear end of the rod needs to go into the center hole at the rear of the engine section.  The rod should fit only halfway into this hole, which it must share with the center spud of the Exhaust Nozzle assembly.  You will note that the center Exhaust Nozzle has a very short mounting spud.

Assembly of the spine should begin with the spine rod being inserted into the Engine Section.  The next item is one of the spacers, followed then by Module Group #11.  Then another spacer, followed by Module Group #10.  Be sure to get the Module Groups oriented properly, with the forward end, indicated by the indentation, facing away from the Engine Section.  Alternate spacers and Module Groups, in numerical order, until you come to #7, the Antenna Module group.  The Antenna Module needs to be glued to the spine rod using a couple of drops of white glue.  This glue should be used very sparingly.

I should point out here that the Antenna Module group is the only one to be glued to the spine rod.  I also need to point out that the slope on the Antenna Module faces to the rear of the ship.

All the other module groups and spacers need to be left unglued, so they can move freely.  The reason for this has to do with reducing the chance of damage, should the model experience any kind of impact.  It is much better if the modules rotate on the spine rod than having to take any impact while remaining immobile.  Of course, this is my opinion and if you would rather glue things together, my only advice to that is to just use white glue.  This way, if it becomes necessary to disassemble the model at a later date, the joint made by white glue is much easier to break loose.

The reason for sticking the Antenna Module to the rod is simple:  it must not be able to rotate.  With the antenna assembly in place, this module becomes top-heavy, thus more likely to rotate out of position.

This would endanger the antenna assembly should it fall off.  I recommend that the antenna assembly be secured using a very small amount of white glue.

With all the modules and spacers in place, fit the 'neck' into place.

You will note that there is a hole in the side of the neck.  This is where the forward end of the spine mounts to the stand.  You will also note that the Engine Section also has a similar hole in its forward end.  Orient the spine so that the hole in the Engine Section faces downward.  The stands are very simple-- just two black blocks and brass rods.  Fit the rods into the blocks.  Fit the other end of the rods into the two holes on the model.

Now you have the entire spine, with Engine Section, mounted to the two stands.  This is now the time to investigate the way the Command Module fits to the neck.

IMPORTANT:  Be sure that the EVA Pod stays inside the CM.  Do not handle the CM with the Pod extended outward.  It just makes things more difficult if it is.

Examine the opening at the rear of the CM.  You will see 3 studs.

These fit into the grooves on the neck.  Inside the CM are 3 9v battery leads.  You can use one, two or three 9v batteries to power the lights in the model.  The batteries fit into the empty spaces inside the CM.  They just sit in there, there is no actual mount for the batteries.  The lights are controlled from the switch at the bottom of the CM.

Hold the CM so the flight deck window is 'level'.  Rotate it slightly to the right and it will fit onto the neck.  Rotate the CM back to level to engage the studs into the grooves.  You may have to rotate it back a tiny bit to get the window to be level.

Now have a look at the Exhaust Nozzles.  To be properly oriented, make note that in each of the 3 faces of the nozzles there are 3 small 'blackened' details.  There is one detail to the side of the two exhausts in each face, and two of the same detail on the other side.

The Exhaust Nozzle assembly should be oriented so the single detail is on the left.  Do NOT glue the Exhaust Nozzle assembly to the Engine Section.  It will fit just fine by slipping the spuds into place and it makes things much easier to fix if damage occurs!!  You may have to adjust the depth of the spine rod as it sits in the center hole, to get the Exhaust Nozzles to fit properly.  Remember, I have made sure of the fit before shipping this model, so I know everything fits correctly!

The last thing is to mount the manipulator arms to the center EVA Pod.

 These arms are really, really fragile.  They do have wire cast into them to reinforce them against breakage, but they are still really fragile.  If one breaks, the wire will insure the part does not separate and makes it easy to glue things back into place.  Just push each arm into its hole in the front of the Pod.  Do not glue, they won't fall out.

The fit of the EVA Pod and its 'docking pad' differs from model to model.  It may slide out easily, or it may take a bit of wiggling to get it to slide forward.  Simply grasp the docking pad and pull outward.  It moves about an inch, but pulling it forward farther than that won't hurt anything.  It is while moving the Pod in and out that you really need to be careful of the arms!

Rotate the modules and spacers to their correct positions, starting with the Antenna Module.  Since the Antenna Module is bonded to the spine rod, when it is rotated, so is the rod.  Once it is positioned correctly, you can rotate the rest without one affecting the others.

Your model is now fully assembled.

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