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Brussels PCC 7000 series

Assembly instructions

1) Glue the chassis bottom plate to cardboard. When dry, score the fold lines (5 in total) with a dead ballpoint and cut out the plate. Don't forget to cut 8 times in front of the scissors symbol, to allow these flaps to bend upwards. Glue the reinforcement plate to cardboard and cut out, then glue the left and right parts to it. Slightly bend upwards the front part of the bottom plate to match the form of the reinforcement plate, and glue them together. After bending the 4 wheels areas upwards, the chassis should look like this :

2) Cut out the body and score on the edge of the dark grey roof surface.

3) Glue the body reinforcement plates to cardboard and cut out when dry. Glue these plates to the body interior, at the edge of the wheels arches, and centre them on both sides. You should have something like this:

4) Glue the 4 large tabs of the roof to the corresponding side of the body. The edge of the coloured part should line up parallel to the edge of the side body panel. This should make the body warp slightly inwards. Make sure this dries thoroughly, because it won't be possible to correct once the body is glued to the chassis assembly. Repeat this procedure for the 4 small tabs. The front (and rear) edges of these should very closely line up to the front (and rear) edges of the body. Assembly at this stage should look like this:

5) Cut out the front and rear panels and the two white strips. Make a slight top fold on the front side at the lower edge of the window, to allow for and easy fit with the body panels.

6) Glue the rear panel in place, starting from the roof. Make sure it is perfectly centred to the roof, otherwise the body will not be symmetrical at the bottom. The rear of the tram should almost have it's final appearance right now :

7) Glue the two white tabs to the front panel, then one side at a time to the side panels. Make sure to line up the 3 panels perfectly, otherwise the body will tend to warp to one side. This is how it looks when done : the 3 panels together should almost make half a circle.

8) Now glue the left and right flaps of the front panel in place, the edge should be flush with the side of the body panels :

9) Glue the body to the chassis, starting with the large centre tabs, these should align perfectly with the chassis, then the tabs at the front and rear doors, and finally the small tabs. Try to let the body warp naturally, do not force it to follow the chassis edges in the front and rear areas.

10) Score and cut out the front bumper parts. Glue the large and small rectangles to cardboard, when dry bend the larger one to match the bumper top and bottom. Depending on the cardboard thickness, it might be necessary to reduce the larger rectangle's length to fit inside the bumper. Also depending on the cardboard thickness, you will need one or both the small grey rectangles to make up for the gap between the body and the front bumper.

11) With a black marker, finish all white edges the bumper, so that it appears to be a solid black structure. The assembled bumper should look like this :

12) Glue the front bumper to the body, the top of the bumper should be aligned with the top of the black line on the sides :

13) Assembly of the rear bumper is pretty similar to the front one, except for the bending of the reinforcement.

14) Glue the rear bumper to the body, the top of the bumper should be aligned with the top of the black line on the sides :

15) Carefully score the destination film assembly and cut it out. Try out the fit before gluing : when cut out perfectly, the visible (yellow) triangles should fit just on top of the white ones.

16) Glue the destination film assembly together :

17) Glue the assembly to the roof as in the picture below. If necessary, apply two tiny drops of glue to triangle's points to keep the part in place against the front panel.

18) Glue the truck assemblies to cardboard, score on the dotted lines, and cut out. Bend the sides as in the picture:

19) Cut out the truck sides and glue them in place. If you want to add more 3D effect, you can glue the separate wheels to cardboard, and glue them on top of the ones on the truck sides.

20) Glue the assembled trucks to the chassis, making sure to align them to the centre of the cut-out on the body :

21) Score and fold both pantograph sheets on dotted line as in the picture :

22) Apply glue to both sides and glue them together. Press firmly and let it dry thoroughly.

23) Carefully cut out the pantograph upper arm with a hobby knife (X-Acto or similar) removing all the white surfaces. Finish with a marker on all visible edges. Bend up the inner arms and glue the bent narrow strip on top of it, exactly where the two inner arms are closest to each other. Cut of the excess length of the narrow strip. Keep the wider strip apart, you will need it later on. Cut out the pantograph's contact rail and its hinge. Finish with a marker on all visible edges. Score the hinge on the dotted white line, and fold to about 75°. Glue the hinge to the contact rail, and finish all edges with a marker.

24) Glue the hinge to the upper arm, making sure it is centred and lined up correctly.

25) Glue the pantograph's base plate and the other parts within the same rectangle to cardboard and let dry thoroughly. Cut out the different parts as in the picture below. Glue the two long strips back to back. This will be the pantograph's front lower arm.

26) Finish the sides of all the parts with a dark grey marker and glue the white part on top.

27) Score the bottom pantograph hinge, cut out and glue it to the base assembly. make sure both front and rear hinges move freely :

28) Cut out these 3 parts and roll into cylinders. The long one will be the pantograph's rear lower arm, the two short ones represent the pantograph springs :

29) Place a drop of glue inside the rear lower arm (cylinder) and slide it over the rear hinge. Score and cut the middle hinge assembly and glue the widest of it's tabs inside the rear lower arm. You should end up with something similar to this :

30) Connect the two remaining hinges with the lower front arm, and when dry glue the upper pantograph assembly to the middle hinge, making sure it is lined up correctly. This was the hard part of the pantograph's assembly :

31) Glue both springs in place as shown below. Make sure their glue joint is facing down so it is out of sight forever. Glue the part we saved at step 23) to the front of the springs, hiding the opening in both the tubes. Your pantograph assembly is now completed :

32) Glue the pantograph assembly on the roof top, making sure it is aligned correctly in both direction. The white area should be completely hidden :

33) Cut out the roof-top box and warp it's sides to allow the flaps to match with the white areas on the roof-top. Fold the excess at the back inwards and glue to the roof-top.

34) Cut out the front and rear ventilation boxes, assemble and glue to the white areas. That's it, your 7000 is ready for service....