Power Car Instructions
Read these important assembly instructions before starting!
Also make sure you've read the General Instructions first.
Note that this will be the most difficult part of your trainset to assemble. You will have better chances of success if you've made the trailers first!
Step 1 Cut out the base of the power unit (part number 2) leaving about 5 mm (1/4 inch) margin around the edge of the part.
Step 2 Find a piece of cardboard slightly larger than the part you just cut out. A cereal box will do nicely. The cardboard will stiffen the base of the model and ensure that it is straight. Glue the part from step 1 to the cardboard. When it is dry, cut out around the edge of the part (cutting off the margin you left earlier).
Step 3 Score the main body (part number 1) at each place indicated by the arrows.
Step 4 Cut out the main body.
Step 5 Mark the folds on the main body. All folds are "peak" folds.
Step 6 Apply glue to flap x, and press it against the back side of the triangular flap on the side of the body, as shown in figure 1 below. Repeat for both sides. Ignore part 4 for now, we will use it later.
Figure 1 Diagram of the nose of the model, showing how parts 1 and 4 fit together.
Step 7 Apply glue to the back side of flap A. Glue flap A onto the base (part 1) so that it wraps around the bottom of the base (see Figure 2). Make sure that the blue marks on flap A align with the blue marks on part 2, and that the green marks on flap A align with the green marks on part 2. This alignment is very important; if you don't get it right the model will be twisted or bent. Also make sure that you don't glue part 2 backwards; it is labelled "front" and "rear". Pressing down on flaps A and B is difficult; try holding the base (part 2) by the edges.
Figure 2 Cross-section of the model. This shows how the parts fit together.
Step 8 Repeat Step 6 for flap B. You can try to reach in the front or back of the model with a finger or other object to press part 2 down onto the flaps.
Step 9 Glue flaps T, U and V to close the ends of the body. Make sure they are centered and aligned exactly, as a slight misalignment will cause your model to be twisted.
Step 10 Fold flap S onto part 2 and glue it down. Make sure the green alignment marks are lined up. Since it's difficult to press down on this area, temporarily insert a piece of cardboard or other flat tool (e.g. table knife) crosswise in the space under part 2 to press against.
Step 11 Repeat the procedure for flap R.
Step 12 Score and cut out the nose, part 4. Mark the folds (all folds are "peak" folds). Bend the sides to give them the necessary curvature.
Step 13 Glue flap G just under the front roof section part 1, as shown in figure 1 above.
Step 14 Apply glue to one half of flap E, the area NOT shaded in gray in figure 1 above. Flap E attaches part 4, the nose, to part 1, the body, and the edges of both parts should align as shown in the figure. Repeat for both sides.
Step 15 Once the glue from the previous step has dried, apply glue to the remaining half of flap E (shaded in gray in figure 1), bend the side of the nose and apply it to the flap. You may need to use a tool to apply pressure to the flap from inside the model, making sure the edge of part 4 aligns with the edge of part 1. (This is difficult, but remember that the rounded shape of the real thing is challenging to model out of a flat sheet of paper!) Repeat for both sides.
Step 16 Fold both flaps F onto the bottom of the model (part 2) and glue them down. Use the red diagonal alignment marks on part 2 as guides.
Step 17 Score part 3, the underbody. Score along its entire length at the six places indicated by arrows, and cut it out.
Step 18 Mark the folds on the underbody. In the order from flap C to flap D, the first and last fold should be "valley" folds and the four others should be "peak" folds. Refer to the blue part of Figure 2.
Step 19 Apply glue to the back side of flap C. Glue flap C onto the back side of the underbody so that you form the shape shown on the blue part of Figure 2 (seen from the end). The colored part of the underbody should slope inwards at an angle of about 30 degrees.
Step 20 Repeat the last step for flap D.
Step 21 Apply glue to the top of the underbody and glue it to the underside of the main body. The underbody should cover flaps A and B. Make sure the underbody is centered, both lengthwise and crosswise.
Step 22 Score part 6, the front wheels, according to the arrows. Also score on the red lines beneath flaps Q.
Step 23 Cut out part 6 and fold it. All folds are "peak" folds. Fold the bottom flaps (unlabeled) to the back of the wheels. These flaps are not glued to anything and are used only for stiffness. Bend the front air dam into a symmetrical curve, so that flap w can be applied to the light gray area on the other end of the part.
Step 24 Glue flap P so that part 6 forms a box. Glue flap w to the light gray area, forming an assembly as shown in Figure 3 below. Fold flaps Q inward, and glue the wheelset under the front of the model so that the air dam is centered under the nose.
Figure 3 Assembly of part 6.
Step 25 Repeat steps 22-24 for part 5, the rear wheelset, but this time without the air dam (a simple box). Glue to the underside of the rear of the model.
This completes the assembly of the TGV power unit. You can now return to the model page.