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1.) Cut
around the templates and tape them to the corrugated cardboard.
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2.) Pierce
through all of the bearing points(marked +) using a drawing pin.
Widen the holes using the 100mm bearing bar.
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3.) Cut
out the internal sections first. The slots should be matched to the
thickness of the cardboard you are using.
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4.) Cut
out all of the pieces.
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5.) Assemble
the middle plate, baseplate, and side pieces as shown
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6.) Check
that the middle plate rests 100mm
(4”)
from the base plate.
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7.)
Glue
the first diaphragm support piece into place. It should be level with
the top of the cut out in the side pieces.
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8.) Fit
the displacer cylinder into place as shown.
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9.) Glue
the second diaphragm support piece in place, about 18
mm (1”)
above the first one.
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10.) Glue the diaphragm
holder into place as shown.
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11.) Pierce two holes for
the bolts that hold the bearing bracket in place. Bolt one of the
bearing brackets in place using a M4
x12 bolt, washer and nut.
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12.) Fit
the crankshaft in place. Thread it through the small holes, not the
larger holes. Bolt the other bearing bracket into place.
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13.) Screw
one of the brass connectors onto a piece of 45mm bearing bar. Push
the flywheel against the brass connector and glue the two together.
Repeat for the other flywheel.
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14.) Remove
the flywheels and connector from the bearing bar and fix them into
place as shown.
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15.)
Fit
the diaphragm over the diaphragm holder.
It should not be stretched tight.
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16.) Glue
the two beam support piece in place as shown.
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17.) Glue
the other beam piece on as shown.
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18.) Widen
the centre hole, so the beam will move freely.
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19.) Cut two small 5mm (¼ “) pieces of spacer material.
Push the beam bearing bar through the side pieces and through the
walking beam, with the small spacer piece either side of the beam..
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20.) Fit main connecting rod into the beam. There should
be spacer material either side.
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21.) Connect the other
end of the main connecting rod into the crankshaft as shown.
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22.) Cut the diaphragm
connecting rod down to size and fix it into the brass connector on
the main con rod.
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23.) Fit the displacer
con rod into place in the same way as the main con rod.
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24.) Tie the displacer wire to the displacer con rod.
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