Suggested tools and glues
- Ruler
- Needle files
- Hammer
- Drill bits with mini finger drill
- Sharp knife
- Tweezers
- Side cutters
- Small snipe nose pliers
- Wet and dry paper
- Rubber bands
- Polystyrene cement (used for Airfix kits)
- Glue 'n' Glaze for fixing windows
- Soldering iron, solder and "helping hands" (not shown) if you do not have the prewired kit
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Wiring
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On/off switch
- Locate the on/off switch, power cables and thicker heat shrink tubing
- Cut one outer tab off the switch - the tab holes are small and you may wish to widen these with a 1mm drill bit in a finger drill to allow the wires to fit more easily
- Cut the red wires attached to the white Mini B power connector and to the white flat lipo connector to 40mm and strip the ends
- Cut the black wires attached to the white Mini B power connector and to the white flat lipo connector to 30mm and strip the ends
- Cut 2 pieces of thicker heat shrink tubing to approx 7mm and 1 piece to approx 12mm
- Slip a shorter piece of heat shrink tubing on the red wire attached to the white Mini B power connector
- Solder this red wire onto the middle switch tab
- Slip a shorter piece of heat shrink tubing on the red wire attached to the white flat lipo connector
- Solder this red wire onto one outer switch tab
- Push each heat shrink tubing on both the red wires so they fully cover the soldered tabs and gently apply a soldering iron to shrink these in place
- Slip the longer piece of heat shrink tubing on the black wire attached to the white flat lipo connector
- Solder the two black wires together
- Push the heat shrink tubing on the black wire so it fully covers the soldered join and gently apply a soldering iron to shrink this in place
- IMPORTANT - make absolutely sure the soldered tabs and black wire join are fully covered by the tubing and there is no possibility of any tabs or exposed wires touching and causing a short
- Make sure the completed switch wiring is the same as the photo
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Motor
- Locate the motor, yellow and orange wires and thinner clear heat shrink tubing
- Cut the yellow wire to 70mm
- Cut the orange wire to 60mm
- Cut 2 pieces of thinner heat shrink tubing to approx 8mm
- Slip a piece of heat shrink tubing on each wire and strip the ends by 2-3mm
- Orient the motor as shown
- Solder the yellow wire to the tab closer to the spindle - the tab is very small so do this carefully and make sure the solder or wire do not touch the metal case of the motor
- Solder the orange wire to the other tab - the tab is very small so do this carefully and make sure the solder or wire do not touch the metal case of the motor
- Push each heat shrink tubing so they fully cover the soldered tabs and gently apply a soldering iron to shrink these in place
- These connections can be fragile so don't bend them until you are ready to put the motor in the frame later
- If you accidentally attach the yellow and orange wires the wrong way round don't worry - it just means you will need to connect them to the motor output pins of the Mini B the other way round so that the loco runs forwards correctly
- IMPORTANT - make absolutely sure the soldered tabs are fully covered by the tubing and there is no possibility of any tabs or exposed wires touching and causing a short
- Make sure the completed motor wiring is the same as the photo
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Connecting and checking the electronics
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Connecting the Mini B and battery
- Lay the Mini B upside down
- Make sure the switch is set to off - the black handle should be pushed so that it does not go over the 2 red wires
- Connect the 2 yellow and orange wires from the motor to the 2 pins under the board with the orange wire plugged onto the outer pin further from the white socket so that loco goes in the correct direction - if you get this wrong you can always swap the wires round later
- Connect the white power plug into the white socket on the Mini B - it is keyed and should only go one way with the red wire on the outer side
- Connect the charged lipo battery - do this carefully as the pins are small so do not try to force it
IMPORTANT! Only use the recommended 3.7V 380mAh lipo battery Please download and read the setup guides from the links below before proceeding further, especially if you have not used a Loco Remote before.
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Electronics check
- Check everything works by turning the switch on
- The blue LED on the top side of Mini B board should do a brief flash
- Connect your smartphone to the Mini B as described in the Mini B setup guide
- Run the controller from your screen
- When going Forward, the motor shaft should be rotating clockwise as you look directly at it - if it is rotating anti-clockwise reverse the yellow and orange motor wires
- You can change the name on the screen (for example to Sylvasprings or Vitacress) and password if you wish as described in the Wi-Fi connection and controller operation guide
- Once you are happy everything is working correctly, turn the switch off and disconnect the components
- Always remember to switch the power off when you have finished running so the battery does not fully drain
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Assembling the loco
If you are planning to paint the kit and/or apply the decals you may want to paint some parts or sub-assemblies first. If you plan to apply the decals, please read these instructions from Endon Valley Custom Decals before continuing.
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Wheels and axles - 1
- Locate the wheels, axles and wheel spacer
- Drive pulleys have already been prealigned on the axles - note they are correctly in slightly different places on the axles
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Wheels and axles - 2
- Use a small hammer to tap an axle through a wheel resting on the red wheel spacer
- Repeat for the other wheels
- Back to back wheel spacing should be 28mm for 32mm gauge which will be set automatically by the wheel spacer
- If you do need to move the pulleys for any reason then the easiest way is to push down on them with your fingers with the end of the axle on a hard surface
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Chassis - 1
- Locate the chassis, frame sides and frame ends
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Chassis - 2
- Position (but do not glue) the frame sides in the chassis
- Fit the axles in the frames and check they rotate freely without binding - if necessary use a 3.2mm drill bit in a finger drill to open the holes slightly
- You now have an option - you can either leave the axles in the frames (checking the pulleys are aligned as in Drive - 2 below) or remove the axles - they are easier to fit when inserted now, but can be fitted later with care
- Glue the frame sides to the chassis making sure they are square to the floor and sides
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Chassis - 3
- Glue the frame ends to the chassis making sure they are square and the rivet coupling pin will pass through freely
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Drive - 1
- Locate the chassis, wheels with axles, motor, motor pulley and O rings
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Drive - 2
- Push the keyed motor pulley onto the shaft - don't push it all the way but leave a 1mm gap on the spindle near the gear box
- Place an O ring over each axle and align the axle pulleys as shown so they are both on the hole in the floor side of the chassis
- Carefully push the axles into the side frames - they will go with a little bending but be careful that the frame does not come unglued from the chassis - if it does then glue it back
- Make sure the axles rotate freely without binding
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Drive - 3
- Push the motor into the chassis from above so that it is held firmly in place
- Slip the O rings over the axle and motor pulleys - tweezers can help
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Grill - 1
- Locate the main body and grill - note the Sylvasprings body shown has an extra space at the front which Vitacress does not have - see Body Differences below
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Grill - 2
- The easiest way to fit the grill is to attach a cocktail stick to the back with Blu-Tack, smear glue on either side of the front and then manoeuvre it in place
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Grill - 3
- Use one of the weights to hold the grill in place while the glue dries - don't remove the backing strip from the weight as you don't want it to get stuck there!
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Body - 1
- Locate the main body and body sides
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Body - 2
- Glue one side in place making sure it is square and aligned with the floor and ends - leave it to dry
- Glue the other side in place
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Body - 3
- Locate the window frames - note that the top has an angled edge
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Body - 4
- Glue one window frame in place with the angled top facing out - make sure that all the edges align with nothing protruding
- Repeat for the other window frame
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Body and chassis - 1
- Feed the motor wires through the floor of the body so that they come out in the engine compartment
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Body and chassis - 2
- The motor should fit snugly in the body
- Be careful not to damage the wire joints to the motor lug as they are fragile
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Body and chassis - 3
- Locate the switch with wiring and the self tapping screws
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Body and chassis - 4
- Push the switch into the compartment in the bonnet with the handle poking through the chassis - the side with the cut off tab should be on the right when viewed from below as in this photo which has the switch set to off
- Use the self tapping screws to secure the chassis to the body to the switch - do them up tightly after checking everything is aligned
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Fitting the electronics - 1
- The switch and motor wires should look like this in the body
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Fitting the electronics - 2
- Lay the Mini B upside down
- Make sure the switch is set to off - the black handle should be pushed so that it does not go over the 2 red wires
- Connect the 2 yellow and orange wires from the motor to the 2 pins under the board with the orange wire plugged onto the outer pin further from the white socket so that loco goes in the correct direction - if you get this wrong you can always swap the wires round later
- Connect the white power plug into the white socket on the Mini B - it is keyed and should only go one way with the red wire on the outer side
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Fitting the electronics - 3
- Push the Mini B into the slot in the body
- It is important that the Mini B is in evenly - use a small screwdriver to carefully bend and guide the yellow and orange motor wires round the Mini B (against the left side in this photo) so they are not under it preventing it from being pushed all the way in the slot
- Connect the charged lipo battery and put it in the battery compartment as shown - do this carefully as the pins are small so do not try to force it
- Repeat all the steps in the Electronics Check above to ensure that everything works and the loco goes in the correct direction forwards - note that the front of the loco is actually the cab end and not the bonnet, so forwards means cab first!
- Once you are happy everything is working correctly, turn the switch off and disconnect and remove the battery
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Windows - 1
- Locate the 4 windows
- The longer rectangular windows are for the front and back
- The shorter rectangular windows (1 for Sylvasprings and 2 for Vitacress) are for the sides
- The trapezoidal window is for a side for Sylvasprings only
- Use Glue 'n' Glaze or similar to fix the windows - polystyrene (e.g. Revell) or super glues will fog the clear windows so don't use them
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Windows - 2
- Start with the front and back windows (the longer rectangles)
- Before removing the protective film check they fit correctly
- Use a fingernail and tweezers to carefully peel away a corner of the protective film on both sides
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Windows - 3
- Run a very thin line of Glue 'n' Glaze around the inside of a front or back window frame
- Remove the protective film from one side only of a window, making sure you do not touch this
- Very carefully sick the window in place - the bottom of the window should be right against the bottom of the frame and there should be a gap of around 1mm from the top of the window to top of the frame - study the photo to see this
- If you do not leave this gap above the top the window then the roof will not fit
- Wait for the glue to dry completely (around 15 minutes) and then peel the protective film from the inside of the window
- Repeat for the other front or back window
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Windows - 4
- Fit the side windows in a similar way
- The trapezoidal window of Sylvasprings should just fit in place inside the front and back windows
- The other rectangular side window(s) only have an overlap of just over 1mm on each side so take care
- As before wait until the glue is dry before removing the inside protective film
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Handles
- Glue the door handles in the holes in the doors - just one for Sylvasprings, and one each side for Vitacress
- Glue the 4 bonnet handles in place (Sylvasprings only)
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Weights
- Do NOT remove the sticky backing from the weights as this will make them hard to position
- Push two 10g weights vertically into the slot in the body next to the battery compartment
- Push two 10g weights into the slot next to the motor which will be covered by the seat
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Seat
- Push the seat firmly into the cab above the weights making sure it is all the way towards the bonnet and flat on the floor - there is no need to glue it as it is a friction fit
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Driver
- Driver Brad from Clavey Models has been custom designed to fit the cab
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Battery
- Connect the charged lipo battery and put it in the battery compartment as shown - do this carefully as the pins are small so do not try to force it
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Body differences
- This photo shows Sylvasprings (left) and Vitacress (right) - note the position of the front weights
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Bonnet top (Sylvasprings only) - 1
- Locate the filler caps and exhaust
- Examine the base of each carefully as they are angled so that when fitted the caps and exhaust will be vertical - the thicker parts should be at the cab end, on the left in the photo
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Bonnet top (Sylvasprings only) - 2
- Glue the filler caps and exhaust pushing them through the holes from underneath the bonnet
- Note the previous comments on the angled bases so that the caps and exhaust are vertical as shown in the photo
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Roof
- Clip the roof in place - glue it only after you have put the driver in the cab!
- Clip the bonnet top in place - do NOT glue this so that you can access the battery
- Cut the end off the rivet to your desired length (around 9mm) so that it can be uses as a coupling pin
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Decals and final comments
- If you want to apply the decals, please read these instructions from Endon Valley Custom Decals
- Use a sharp knife to cut out each decal - the Sylvasprings logos go on each side of the bonnet between the bonnet handles - the Vitacress logo goes on the front of the cab
- Although the Endon Valley instructions recommend applying a gloss coat first, I found that the decals will adhere directly to the printed plastic sides of the battery box but should still be covered with a clear spray varnish
- The loco is capable of pulling a few lightly loaded wagons
- The axles rotate directly in the axle boxes without bearings
- Add a very small drop of thin oil to each axle box for lubrication
- Keep the oil off the O rings
- Power it up and enjoy
- Always remember to switch the power off when you have finished running so the battery does not fully drain
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Assembling the wagon
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3D printed parts
- Black: 4 wheels, chassis, 2 frame sides, 2 frame ends, 2 frame centre bars, 3 coupling bars
Other parts
- 2 axles 42mm long
- 2 rivets for coupling
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Wheels and axles
- Use a small hammer to tap an axle through a wheel resting on the red wheel spacer supplied with the loco
- Repeat for the other wheels
- Back to back wheel spacing should be 28mm for 32mm gauge which will be set automatically by the wheel spacer
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Chassis - 1
- Position (but do not glue) the frame sides in the chassis
- Fit the axles in the frames and check they rotate freely without binding - if necessary use a 3.2mm drill bit in a finger drill to open the holes slightly, then remove the axles
- Glue the frame sides to the chassis making sure they are square to the floor and sides
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Chassis - 2
- Glue the frame centre bars onto the 2 bars under the chassis - they should form a U channel angle iron when viewed from the side
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Chassis - 3
- Locate the frame ends - note that one side has a slightly raised central part and the other side is smooth
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Chassis - 4
- Glue the frame ends onto the bars at the end of the chassis - the raised part should be inside the U shape with the smooth part visible from the bottom
- Make sure that the ends are aligned so that a rivet pin can pass through the holes
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Chassis - 5
- Carefully push the axles into the side frames - they will go with a little bending but be careful that the frame does not come unglued from the chassis - if it does then glue it back
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Coupling bars
- Cut the end off the rivets to your desired length (around 9mm) so that they can be uses as coupling pins
- 3 different length coupling bars are provided with each wagon - use the shortest that will allow the wagons to go round your tightest radius curves
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Seat 3D printed parts (optional)
- Black: 2 side supports
- Brown: main seat, 2 back rests, top rest
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Seat - 1
- Locate the holes on the inside of a support and the matching lugs on the side of the main seat
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Seat - 2
- Glue the main seat to a support as shown - the smooth side of the seat faces up
- Make sure the parts are perpendicular to each other and leave them to dry
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Seat - 3
- Once dry, repeat for the other support
- Make sure the parts are perpendicular to each other and leave them to dry
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Seat - 4
- Glue one back rest to the supports as shown - the smooth side of the back rest faces out and the notches fit in the support top bars
- Once dry, repeat for the other back rest
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Seat - 5
- Glue the top rest in place
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Seat - 6
- Glue the completed seat centrally on the top of a wagon
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Watercress tubs (optional)
- Glue the 3 watercress tubs on the top of a wagon if desired
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