Lancia 037 Rally Project

Page 1:  Assembly

   

The Lancia comes in a small box with beautiful box art.  When I opened it, I was initially chagrined at what appeared to be a polycarbonate body, but then I realized it was just the interior with driver figures.  Note the tire foams on the right, a rarity for a Tamiya model out of the box.




The TA-02 is a "real" touring car and therefore has a lot of parts, but sadly did not come with ball bearings out of the box.  Easy to rectify, but I shouldn't have to.


   

It is kind of amazing how many parts there are in Step 1 which builds the rear ball differential.  I count at least 30.  First the 8ea 3mm balls are inserted into the main spur gear using grease.  A thrust washer goes on either side followed by a pressure plate which will be used to squeeze the washers and balls and provide the splined connection to the outdrives.  Next come a stack of Belleville washers (or "disc springs").  There are 2 on the inside of the thrust bearing and 3 on the outside.  These provide a spring rate low enough to make the squeeze adjustable.  If you clamped directly onto the balls a tiny turn of the nut would produce a huge change in clamping pressure, but with a stackup of softer springs you can make finer adjustments.  The thrust bearing must be built up from 6ea 1/16" balls.  I found it interesting that one set of balls is metric and the other Imperial units.  Finally a bolt is installed which is used to clamp everything up and make adjustments.  The instructions say nothing about how to adjust the ball differential properly, so you need to already know what you are doing.


   

Now the differential unit is installed in the pearl gunmetal colored housing.  Plastic bushings are called for in the instructions, but naturally I swapped them out for ball bearings.  The right hand photo shows the other gearbox half installed.  Interestingly, the gearbox connects front to back rather than side to side.


   

The standard 540 motor bolts to an indexing motor mount which supports pinion gears from 16 to 21 teeth.  The kit supplied gear is the highest speed gear, the 21 tooth.  The instructions say never to use any other motor or pinion gear which seems like a strange thing to say for a touring car like this.  For now I will obey, but I intend to rebel later.


   

The weakest point in the drivertrain must surely be this bevel gear which is built into the spur.  As you can see in the right hand image, the bevel isn't needed to drive the rear wheels, but does turn the corner to drive the propeller shaft which runs to the front wheels.




With the rear gearbox buttoned up we can add the suspension arms, the dogbones, the hubs, and the drive cups.  Everything attaches to the gearbox housings with screw pins.


   

You might expect to see basically the same differential and gearbox up front, but you'd be wrong.  In front we get a standard open gear differential.  It is not oil filled so the resistance is not really adjustable.  The front housing is the same interesting color.


   

The front uses the same type of bevel gears.  I say they look weak, but that's really only in comparison to the other gears.  The pitch and face width are pretty large and certainly adequate for the kit supplied motor.  We'll see if they hold up to something stronger.  Note the tiny 5x8 bearing on the bevel gear shaft.  It won't support much load.  The long cantilevered mounting arm of the gearbox housing shown in the right hand image also seems like a potential weak point.


   

Now I've enclosed the front gearbox and installed the front suspension arms, C-hubs, and steering knuckles.  The front arms are pinned with a big u-bolt as shown.  I'm not sure why the steering knuckles are blue since they seem to clash with the rest of the chassis a bit.  They are made from a harder and stiffer plastic than the arms.


   

The kit uses standard oil filled CVA dampers which use the parts shown.  All 4 are identical including the springs.  It helps to have an E-clip tool and a shock pliers when building them.




The front and rear gearbox assemblies are modular which means they can be removed intact from the vehicle and serviced or cleaned.  This image shows the completed front and rear assemblies with the shocks installed, ready to attached to the chassis.


   

The main part of the chassis is a one piece bathtub.  The battery sits in the lateral slot with a cover over the top which will support the electronics.  Like many older vehicles, this one is specifically sized to fit a rounded stick pack and will have trouble with anything else.  The steering servo connects to a dual bellcrank system.  No bearing on the cranks and they are connected together with a Z-rod which means there is plenty of slop in the steering.


   

Now the front and rear suspension assemblies can be installed and it finally starts to look like a car chassis.  The front bumper is a truly prodigious chunk of plastic.  I thought of removing it for scale, but it actually hides pretty well with the body on and will do a good job of protecting the shell.  The rear bumper, on the other hand, is just a little nubbin.  To complete the rolling chassis I've installed the wheels and tires.  The wheels are a very nice replica of real rally wheels and look excellent.


   

The gorgeous hard shell body comes molded in white, but that didn't stop me from painting in white anyway.  The shine is much better that way.  Then there was the long arduous process of applying the stickers.  I would much have preferred water slide decals at this scale because large stickers are very difficult to keep straight and free of bubbles.  They came out pretty well in the end.  There are also plenty of other details to paint including the front marker lights, tail lights, heater intake grilles, and wipers.  The model comes with transparent tinted windows.




Unlike most touring cars, this one even comes with a set of drivers.  This starts as a molded sheet which must be trimmed and painted.  The driver's heads and the steering wheel are separate parts.  Painting took quite a long time, but it really improves the realism of the car.


   

Here are some final shots of the car once fully detailed and clear coated.  I chose not to paint the black trim around the windows because I was too afraid of screwing it up.  I did mask and paint the louvers on the rear bumper.

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