XCS Instructions.pub
Transcription
XCS Instructions.pub
ARCOR & ROAR NATIONAL CHAMPION KSG Motorsports 319 1/2 Samlola Rd. Blountville, Tn 37617 423-323-3494 We are pleased that you have purchased the most complete and competitive 1/10 oval car available today. The XCS (Xtreme Corner Speed) was designed and tested by Jim and Andy McClellan (2002 Arcor, Norrca, and Roar Pro Mod National Champion). We have tested and changed the design several times to ensure that the kit you have purchased will be very competitive when it hits the track for the very first time. Some features of the XCS include the ability of offsetting the rear pod .300 without having to purchase any extra components other than a set of offset hubs. The front of the chassis is slotted so that you can change the cars wheel base by sliding the front end front to rear. We have included a custom CNC machined center shock mount. This mount is functional and also light weight. You can adjust the center shocks height in 7 different positions. A never seen before feature for the side shocks is the ability to change their outer mounting position in 4 different places without the need of different length ball studs. The aluminum servo mounts have been drilled and tapped with 3 sets of holes in the bottom so you can move them to different locations without having to redrill your chassis several times. CNC machined aluminum caster blocks have been included so that you can adjust the camber gain of the front end. Also titanium tierods have been included. The battery tray has a place so that you can mount your speed control behind the battery pack. This makes for short wires on the speed control and also adds left side weight to your car. The pods bulkheads have been CNC machined and have already been lightened for you. The bottom plate of the pod has a unique feature. You can change the amount of rear steer that you have by changing two rear steer slugs that go in it. These slugs keep the pod and t-plate aligned very accurately. All of the parts in the kit have been track tested and proven. And if that’s not enough we have even anodized all the aluminum blue to make this the most complete kit you have every purchased. Please follow all of the instructions to insure that when finished you have a perfectly built race car. 2 Your XCS is manufactured from woven graphite sheet and cut out on a CNC milling machine to hold close tolerances. Remove the chassis and graphite components and wet sand the edges to remove any sharp burrs from the machining process. The battery tray edges should be filed to provide a smooth angled edge for the batteries and tape to sit against. Your car kit comes with an Associated strut style front end. Follow the instructions included in the front end for assembly. We have included a set of KSG aluminum adjustable caster blocks (Bag A). These caster blocks will take the place of the stock ones that come with Fig. 1 the front-end kit. The bottom hole is the stock position and the other 2 holes can be used to change the camber gain of your front end. You will need to use the four 2-56 x3/8 SHCS After the front end is completely assembled each side needs to be mounted to the chassis. We have included four .100 aluminum spacers to go between the chassis and front-end assemblies. (Bag A) You will need to use the four 8-32x1/2 FHCS provided in the front end kit to attach the front end to the chassis. You need to leave Fig. 2 these screws just loose enough so that you can slide the assembly front to back. If you have a set of calipers you can measure the placement of the assemblies by checking the distance from the front of the chassis to the front of the assembly. If you don’t have any calipers just slide the assemblies all the way to the front or back for the wheelbase you want. When the assemblies are in place tighten the four screws securely (Fig. 2). 3 The next step is very critical, so take your time in mounting the servo. (Bag A) The aluminum servo mounts are drilled with three holes so that you can move the servo front to rear, to adjust bump steer and ackerman, without re-drilling your chassis several times. One critical item is to make sure the servos output shaft is centered with the centerline of the Fig. 3 chassis. For additional information and drilling procedures refer to the Associated front-end manual. The servo will be mounted to the servo mount with the four 4-40x3/8 aluminum screws provided in the front-end kit. The mounts are fastened to the chassis with two 4-40x1/4 FHCS. After the servo and front end are fastened to the chassis, you can attach the front bumper by using the two 8-32x3/8 FHCS and two flat 8-32 nuts found in the front-end kit. The two short body posts (Bag B) will be fastened to the bumper by two 4-40x3/8 BHCS. You can place the body post in any of the three provided holes. Also place one of the provided collars on each body post and secure each of them in place with the 4-40x1/8 set-screw (Fig. 3). (Bag C) The rear aluminum cross mount is used to mount the rear body posts and side shock outer mounts. Assemble the cross mount so that the side shock mounts will be to the front of the car and the one mount with the pad (which is for your speed control switch) is to the left side. You will use four 4-40x1/4 BHCS to Fig. 4 attach the mounts. Next you will need to place one 4-40 ball-stud in each side shock mount. The ball end of the stud will need to go toward the rear of the car. Place an aluminum locknut on each of the studs and tighten them in place. You can choose to use any of the four mounting positions provided. Next you can install the rear body post mounts. They will go on top of the aluminum cross mount. They will point to the rear and the outside of the car. Use two 4-40x1/4 BHCS to fasten them in place. Next attach the two long body post to the mounts with two 4-40x3/8 BHCS. Also place one of the provided collars on each body post and secure each of them in place with the 4-40x1/8 set-screw. Lay the cross mount assembly to the side for now. It will be fastened to the chassis later (Fig. 4). 4 (Bag D) We are now going to assemble the pivot ball sockets and fasten them to the t-plate. *We suggest using 600 grit sandpaper to sand the steel balls and polishing them with polishing compound. * The sockets consist of two halves and one steel ball. Place the socket half with the shoulder on it into the tplate. Next , place the steel ball into the socket and Fig. 5 then place the sockets top half onto the ball. Now use four 2-56x5/16 BHCS to fasten the socket to the t-plate. Repeat this procedure for the other pivot socket. You will need to make sure that the balls move freely in the sockets when the screws are tightened. This will insure proper operation (Fig. 5). We are now ready to assemble the rear pod. (Bag D) Take the bottom plate and lay it on a flat surface with the long ear of the bottom plate pointing to the right. Now you will need to take the 0-degree rear steer slugs (Also available in ½ deg increments ) and look at the shoulder on them. If you look at the end opposite to the end with the hole you will notice that Fig. 6 it has a flat side. This makes them so that they will only go in the bottom plate in one direction. Look at the bottom plate to see which way they go in and then press them into the bottom plate. It is also helpful to take an x-acto knife and slightly bevel the edges where the slug fits into the bottom plate. This will help get it started into the bottom plate as this is a fairly snug fit. You may have to use a bolt, nut, and washer to pull the slug into place. You can put them in either the standard or offset position (Fig. 6). Now we will attach the t-plate to the bottom plate. You will need to use three 440x3/8 BHCS and three 4-40 aluminum locknuts. Screw the BHCS into the front holes of the bottom plate. All of the screws in the pod will fit tight to insure 5 proper alignment. Next place the .100 aluminum Fig. 7 spacer onto the center screw. Place the t-plate over these screws and fasten it with the locknuts. Attach the left and right bulkheads to the bottom plate with four 4-40x1/4 BHCS. Before we attach the top plate we need to place three ball studs in it. You will need to place them in the correct position for standard or offset position. Use three locknuts to fasten them. We also need to place a 4-40x1/2 Stud in the back hole of each bulkhead. Just screw them in by hand until they stop. Now place the top plate over the two studs and place two 4-40x1/4 BHCS in the front holes. Screw the wing mounts onto the studs in the top of the bulkheads. Try to tighten them so that one of the four holes in them points to the rear of the pod. Place two 4-40x1/4 SHCS in these holes for fastening the wing (Fig. 7). Let’s assemble the battery tray next. (Bag E) Fasten tray mount to tray using three 4-40x3/8FHCS, 4-40 washers, and lock-nuts. Notice that tray mount will work in either direction, the only difference being that with pointed end of mount to the rear, the farther back the tray will slide. Also note that slots in mount are on top of the tray. Next fasten two .800 standoffs to front of tray with two 4-40x1/4FHCS. Attach transponder mount to the top of standoffs using two 4-40x1/4BHCS. This completes battery tray and mount (Fig. 8). We are now ready to mount everything to the chassis plate. Fasten battery tray assembly to the chassis using three 4-40x3/8FHCS and lock-nuts. Next, position front t-plate pivot ball over the front t-plate hole in chassis and fasten with 4-40x1/2FHCS and lock-nut. The rear t-plate pivot ball is fastened with a 4-40x3/8FHCS which bolts into the center hole of the aluminum cross mount. Finish mounting aluminum 6 Fig. 8 Fig. 9 cross mount with two 4-40x1/4FHCS, making sure that body posts are toward the rear of the car. The nerf wing is fastened with two 4-40x3/8FHCS and locknuts (Fig. 9). Your XCS comes with Associated VCS side and center Fig. 10 shocks. Build the side shocks according to the instructions supplied by Associated and the center shock with the instruction found on page 10 of the manual.After the shocks are built, thread one ball cup on each end of the side shocks. Measure the overall length of the shocks and try to make both of them the same length by adjusting the ball cups. Snap the shocks onto the ball studs with the threaded shock nut end toward the outside of the car. Thread the long ball cup provided onto the center shock shaft. Next fasten the antenna tube to the center shock mount using a 4-40x1/8 set screw. Attach the center shock mount to the chassis using two 4-40x1/4FHCS. You may choose any of the mounting positions, but you will have to adjust the center shock length by using different length ball cups. Next snap center shock ball cup onto ball stud on the top plate. Insert fuel tubing , (supplied with center shock mount) into the shock cap and fasten this end of shock to the shock mount using 4-40x1/2 SHCS. Be careful and don’t over-tighten the cap-screw. You will need to adjust the rear pod droop by lengthening or shortening the ball cup on the center shock (Fig. 10). (Bag D) Install the #2 ride height adjusters into each of the rear bulkheads. Then place a 1/4x3/8 flanged bearing into each of the ride heights. (Bag F) Take the 1/16 pinning material and pin both the diff hub and the axle flange. Install the 12 diff balls into the outer ring of holes in the spur gear. Also apply a small amount of diff lube to each of the balls. Place a 1/4x3/8 unflanged bearing into the center of the spur gear. Take the 1/4x3/8 flanged bearing and place in the diff side of the diff hub. Fig. 11 7 The 1/4x3/8 un-flanged bearing goes on the outside of the diff hub. Now place one of the notched diff rings onto the axle making sure that the pin aligns in the notch. Now slide spur gear onto axle. Next slide diff hub with diff ring onto axle and down against spur gear making sure that both pins stay aligned in the diff rings. Slide diff cone over outer end of axle with the small end toward the bearing. Secure with the 8-32 nylon lock-nut and tighten the nut so that there is a small amount of drag on spur gear. You can adjust the tightness of the nut to suit different track conditions (Fig. 11). We are now ready to place the axle assembly into the rear pod. (Bag F) Place the .025 axle shim onto the axle and slide axle assembly through the rear axle bearings in the rear pod. Make sure the axle slides through freely. Now slide the left side blue axle spacer and left side clamping hub onto the axle and Fig. 12 adjust end play to a very slight amount. Tighten the clamping hub to complete the installation. Make sure that the axle spins freely. If axle does not spin freely, recheck the end play (Fig. 12). The only thing left to install is the electronics, motor, batteries, and tires. You are now ready to go racing. Good luck and we hope to see you in the winner’s circle (Fig. 13). 8 Fig. 13 BAG CONTENTS Bag A L&R caster block Twelve diff balls Four 2-56x3/8 SHCS Two .078 hinge pins Four .100 front end spacers Two titanium turnbuckles Two servo mounts Bag B Two 2 ½ body posts Two 3 ½ body posts Four body post collars Four 4-40x1/8 set screws Four body clips Bag C Rear aluminum cross mount Side shock & body mt assembly Bag D Two pivot balls Two pivot ball sockets One bottom plate One top plate L&R bulkheads Two 0 degree slugs One .100 spacer Two wing mounts Ride heights Bag E Battery tray Battery tray mount Transponder mount Two .800 standoffs Bag F Right side hub Left clamp hub Graphite axle Two diff rings One 1/16 pin One .250 spacer One diff cone One 8-32 locknut One .025 axle shim 120 tooth spur 9 STEP 1 STEP 2 STEP 4 STEP 5 10 STEP 3 We want to again thank you for buying our product. To thank you we want to introduce you to a special Friend of ours. He loves and cares for us and has given his all for us. You may already have met Him and know Him personally. If so I’m sure you would agree that there is no greater Friend to be found. If you haven’t met Him yet we want you to know who He is and what He has already done for you. Our Special Friend is the Lord Jesus Christ. He already knows you, He loves you and He wants you to live eternally with Him. How can we be so sure of this? In the Bible Jesus said in John 3:16 “For God so loved the world, that he gave his only begotten Son, that whosoever believes in him should not perish, but have everlasting life.” Read this again and this time substitute your name in the blanks to see just what the Lord thinks about you: For God so loved _____, that he gave his only begotten Son, that if ______ believes in him he or she should not perish, but have everlasting life. This is how He feels about you and what He has already done for you. There is no greater Friend that you could ever have. You may ask why this is so special and what’s the big deal? Look at the Bible with me for a minute: In Romans 3:23 we read “all have sinned and fall short of the glory of God”; Romans 6:23a says “the wages of sin is death”; Romans 5:8 tells us that “God demonstrates his love for us in this: While we were still sinners, Christ died for us”; Romans 6:23b says that “the gift of God is eternal life in Christ Jesus our Lord”; Hebrews 9:27 tells us that “man is destined to die once and after that to face judgement.” The name of our car is XCS xtreme corner speed but it can also stand for xtreme cleansing source because that is just what our Friend Jesus is: Isaiah 1:18 “Come now let us reason together, says the Lord. “Though your sins are like scarlet, they shall be as white as snow, though they are red as crimson, they shall be like wool.” Psalm 51:7 “…wash me and I will be whiter than snow”. Acts 2:16 “…be baptized and wash your sins away, calling on his (Jesus) name.”1 John 1:9 tells us “ If we confess our sins, He is faithful and just to forgive us our sins and cleanse us from all unrighteousness”; John 20:31 “These are written that you might believe that Jesus is the Christ the Son of God and that believing you might have life through His name.” Jesus has already paid the penalty for our sins and offers us each his free gift of salvation. Ephesians 2: 8-9 says, “For by grace you have been saved through faith, and that not of yourselves; it is the gift of God, not of works, lest anyone should boast.” Romans 10:9 tells us “ if you confess with your mouth the Lord Jesus and believe in your heart that God has raised Him from the dead, you will be saved.” There is much more I would like to share with you about my Friend but space doesn’t allow at this time. If you want to talk or have questions feel free to call us. Thanks and God Bless, The McClellans Jim, Andy and Becky 11 Part # KSG-1000 KSG-1010 KSG-1011 KSG-1012 KSG-1013 KSG-1014 KSG-1015 KSG-1016 KSG-1020 KSG-1021 KSG-1022 KSG-1023 KSG-1024 KSG-1025 KSG-1026 KSG-1027 KSG-1028 KSG-1029 KSG-1030 KSG-1031 KSG-1032 KSG-1033 KSG-1034 KSG-1035 KSG-1036 KSG-1037 KSG-1038 KSG-1039 KSG-1040 KSG-1041 KSG-1042 KSG-1046 KSG-1047 KSG-1048 KSG-1049 KSG-1050 KSG-1051 KSG-1052 KSG-1053 KSG-1054 KSG-1055 KSG-1056 KSG-1057 KSG-1060 KSG-1061 KSG-1062 KSG-1063 KSG-1064 KSG-1065 KSG-1066 KSG-1067 KSG-1068 KSG-1069 KSG-1070 KSG-1071 KSG-1072 12 Description XCS Car Kit XCS Chassis XCS Nerf XCS Bumper XCS Top Plate XCS Bottom Plate XCS VCS Side Shock Blue XCS Knurled Alum VCS Shock Nuts Blue XCS Solid T-Plate Straight XCS Solid T-Plate Bias XCS T-Plate 1/8 Slot Bias XCS T-Plate 3/16 Slot Bias XCS T-Plate 1/4 Slot Bias XCS T-Plate 5/16 Slot Bias XCS T-Plate 3/8 Slot Bias XCS T-Plate Sockets XCS T-Plate Balls Steel XCS Alum. Wing Mts. XCS Right Bulkhead XCS Left Bulkhead XCS 0 Deg Slug XCS .5 Deg Slug XCS 1Deg Slug XCS 1.5 Deg Slug XCS 2 Deg Slug XCS .5-2 Deg Slug Kit XCS .100 Center Spacer XCS Ride Height Set XCS Shock&Body M Assy XCS Alum. Cross Mnt XCS Battery Tray Asy XCS .800 Standoffs XCS Right Hub XCS Left Hub XCS Right Hub Offset XCS Left Hub Narrow XCS Diff Rings XCS Diff Balls XCS 120 Spur Gear XCS Rear Axle Brg Set XCS Graphite Axle XCS Diff Cone XCS .250 Axle Spacer XCS Alum. Adjustable Servo Mts. XCS Blue Ti. Tierods XCS Alum. Caster Blocks XCS Front End Kit XCS 1/8 Frt Brg XCS 3/16 Frt Brg XCS Alum. Adjustable Shock Mnt. Blue XCS Center Shock Blue XCS 4-40 Alum. Locknuts XCS Ball Studs XCS Screw Kit XCS Front Body Posts XCS Rear Body Posts Pkg. Qty. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 2 2 1 1 2 2 2 2 2 8 4 3 1 1 1 2 1 1 1 1 2 25 1 1 1 1 1 2 2 2 1 4 4 1 1 10 5 1 2 2 Retail $569.99 $79.99 $5.99 $24.50 $15.99 $15.99 $17.99 $7.99 $7.50 $7.50 $7.50 $7.50 $7.50 $7.50 $7.50 $3.00 $4.00 $8.99 $27.99 $27.99 $8.99 $8.99 $8.99 $8.99 $8.99 $28.99 $4.99 $2.99 $14.99 $29.99 $34.99 $4.99 $28.99 $28.99 $29.99 $28.99 $3.99 $2.99 $4.00 $24.99 $24.99 $4.99 $4.99 $12.99 $9.99 $39.99 $40.99 $19.99 $19.99 $42.99 $21.99 $4.49 $6.99 $14.99 $2.99 $2.99 Prices subject to change without notice.(2002)