Step 1: Assemble the front arms to the suspension mounts using CW2204, CW3206, CW4233, and CW5203 as shown in Fig.1

Step 2: Assemble the axle (CW7201) into the steering block (CW3202) as shown in Fig 2. Assemble the steering block (Fig 2) and caster block (CW3205) with the king pin (CWCW7202) as shown in Fig 3 and Fig 4. Note: Apply Loctite on the set screw that goes against the king pin. 

Step 3: Assemble the caster block assembly shown in Fig 3 and the arm assembly shown in Fig 1 as shown in Fig 5 using a hinge pin (CW4237).

Step 4: Repeat above process for other side of car.

Step 5: Connect the arm assemblies (step 3 & 4) to the shock tower as shown in Fig 6 using the 4-40x5/16 (HDW003) screws. Note: Use Loctite on the screws and make sure the countersinks on the shock tower are facing forward.

Step 6: Please read carefully. Use the (10) ¼ inch ball links (BMSP056) and (2) shock rod ends (AE6471). (NOTE: (4) of the 4-40 ball ends are smaller than the others as shown in Fig 7. These will be used at the inner connecting points of the camber and steering links.) Screw the ball links onto the turnbuckles as shown in Fig 7. Assemble three pairs of turnbuckles. Two of the links are used between the steering rack and the steering blocks. Two will require trimming 0.125"(1/8 inch) off the ball links, Fig 8. These links are used for the upper camber link between the shock tower and the caster block. Two links will have one trimmed (0.125") ¼ inch ball link on one side and a shock rod end (AS7217) on the other, Fig. 9 and are used on the back of the car. (Set them aside for later use)

Step 7: Please read carefully. Attach the camber links to the shock tower using one 4-40X1/2 FHCSC(HDWR-005), one #4 WASHER(HDWR-032), and one 4-40 LOCKNUT(HDWR-010). Attach the other end of the camber link to the caster block with one 4-40X1/2 BHCSC(HDWR-001) and one #4 WASHER(HDWR-032). Next attach one end of the steering link to the steering block with one 4-40x5/8 SHCSC(HDWR-019) and one #4 WASHER(HDWR-032). Attach the other end of the steering link to the steering rack with one 4-40x5/8SHCS (HDWR-019), one #4 WASHER(HDWR-032) and one 4-40 LOCKNUT(HDWR-010). Mirror this procedure for the other side of the car. Insert the 4-40x7/8 SHCSC(HDWR-021) in the top outermost hole of the shock tower. Fasten with a #4 WASHER(HDWR-032) and a 4-40 NUT(HDWR-015). The final assembly is shown in Fig. 10 below.

Step 8: Assemble front suspension assembly to chassis using six 4-40x3/8 FHCSC. Your BMS sprint car has two chassis wheelbase configurations. We recommend using the longer configuration for new cars. These are the set off holes furthest forward on the chassis.

Step 1: Use Mugen part numbers BMSP080 (JO110), BMSP083 (DO105R), BMSP077 (TO113), BMSP082a (TO137), and BMSP073 (HO254), in this step. See Fig. 1.

Step 2: Modify the hub carriers BMSP077 (with a Dremel tool) as shown in Fig. 2 through Fig 5.

Step 4: Connect arm assembly to rear suspension mount (BMSP004) with hinge pins (BMSP035). Use set screws (HDWR-016) to hold hinge pin in place. NOTE: Use Loctite or RTV silicon on set screws!! Make sure the arm move freely on the pin.

Step 5: Insert a bearing (BMSP071) into each of the bearing adapters (BMSP065). Place the bearing adapters (BMSP065) into the hub carriers. (Fig 9) Install the bearing and adapters into both the inner and outer side of the hub carrier. (Fig 10,11)

Step 6: CVD ASSEMBLY

Once assembled the axle can be placed thru the bearings. Slide the silver spacer on the CVD before placing it thru the axle. Slide the axle thru the bearings in the hub carrier. Install three of the darker spacers to the outside of the axles. Place the spacer (AE9608) to the outside of the washers. Note: Make sure to place the spacer with the flat to the outside. Then place the spring pin into the hole in the axle.

                                                        Left Side Pictured

Repeat this procedure for the other side of the car. Set the arm assemblies aside until later.

Differential Assembly

Step 1: Place the 10mm x 15mm flanged bearing (BMSP096) over the differential halves (BMSP084) as shown in Fig.2. Press the bearing on with the flange to the inside.

Step. 2

These parts will be needed to assemble the differential:

Step 3: Place one outdrive (BMSP054) into the differential half with the belt teeth (BMSP084) as shown in Fig 3. Note: Apply a small amount of grease on the shaft

Fig.3

Step 4: From the inside, place a rubber o-ring (BMSP075) over the outdrive shaft. Place two of the larger washers (BMSP074) over the same shaft on top of the o-ring. Place one of the roller pins (BMSP083) thru the hole in the outdrive. When the pin is centered on the shaft, place one of the large spider gears over the outdrive shaft, aligning the pin with the slot in the back of the gear. (See Fig.4 and Fig.5) Place the Gasket (BMSP072) into this differential half as shown in Fig. 6

        

         Fig.4                                      Fig. 5                                               Fig. 6

Step 5: Repeat the same procedure for the other side, except for the gasket.

Step 6: Place 2 of the smaller gears onto one of the gear shafts. Build 2 of these as shown in Fig. 7. Place one of the assemblies into the diff half that does not have the belt teeth. (Fig. 8) Note the flats on both of the gear shafts. When the other assembly is placed into the diff half make sure the flats are overlapped as shown in Fig. 9.

     

                Fig. 7                                               Fig. 8                                       Fig. 9

Step 7: Place the differential halves together, rotate the halves until you feel them fall into place. Screw the diff halves together using the #4 self-tapping screws (HDWR-040).

NOTE: Assemble the differential dry. Check to make sure the diff is not too tight by holding the center and turning the outdrives. If the gears are too tight or too loose, adjust this with the shims in Step 4 (BMSP074). Once the diff is adjusted, remove the screws and place the grease (BMSP093) onto all of the gears.

NOTE: In place of grease, you can use a number of different diff oils or even shock oil to change how the diff feels and works. The heavier oil will make the differential stiffer which will result in more of a posi differential. Also the o-rings that are with the gears can be placed on the back side of the smaller gears for more drag.

  

Fig.10                                                                                                    Fig. 11         COMPLETED DIFFERENTIAL

Step 8: Belt drive transmission. Cut the 3 pins from the pulley-brake adapter (BMSP078) using a dremel with a cut-off wheel. See Fig. 12

          

Fig.12                                                                        Fig. 13

Step 9: Place the 5 x 10mm bearing (BMSP070) into the transmission side plates (BMSP023). (Fig. 13) NOTE: The flanged part of the bearing is facing up.

      

              Fig .14                                                                                Fig. 15                                                                      

Step 10: Slide the brake-pulley adapter (BMSP078) over the top pulley shaft (BMSP009-01) making sure the flat on the shaft and the set screw are aligned. See Fig 15. Slide the adapter so the set screw is over the flat but do not tighten at this point.

Step 11: Place the Shaft into the left side transmission plate. Slide the front pulley (BMSP084) over the square part on the pulley adapter. Install the E-clip into the groove to hold the gear in place.

             Fig. 16                                                                                                    Fig. 17

Step 12: Place the differential with the belt side toward the transmission plate as shown in figure 17.

Step 13: Install the belt (BMSP018) over the 2 pulleys. Once the belt is in place, rotate the outdrive while aligning the front pulley. When aligned, tighten the set screw on the adapter. Note: Make sure to use loctite on the set screw. Place the right side transmission plate over the front shaft and outdrive. Note: Pull the front shaft forward to get the bearing over the shaft.

  

               Fig. 18                                                            Fig. 19

Step. 14: Using (4) 4-40x3/8" BHCSC (HDWR-037), install the left side bulkhead (BMSP007) and the right side bulkhead (BMSP008) as shown in Fig.20. Note: Be sure to use loctite on these screws.

Fig. 20

Step 15: Turn the transmission upside down and install the 2 transmission mounts (BMSP011) using 4 of the 4-40 x 3/8" BHCSC (HDWR-037). (Fig 21 & 21a)

  

           Fig. 21                                                             Fig.21a

Step 16: Install the rear shock tower (BMSP002) to the transmission using 4 of the 4-40 x 3/8" FHCSC (HDWR-007). Note: Be sure to use loctite on these screws.

  

          Fig. 22                                                                                             Fig. 23

Step 17: Use the (2) 4-40 x 3/4" FHCSC (HDWR-006), (2) #4 flat washer (HDWR-032) and (2) 4-40 nuts (HDWR-015) for the shock posts. Install the 2 screws in the most outward hole. (Fig. 23)

Step 18: Using the rear turnbuckles that you built in section 1 and (2) 4-40 x 5/8" FHCSC (HDWR-008), install the associated end of the turnbuckle into the bulkhead and fasten with the 4-40 x 5/8" FHCSC using loctite. (Fig. 24)

Fig. 24

Step 19: Install the drive shaft roll pin (AE7665) into the hole on the front pulley shaft (BMSP009-01). (Fig. 25) Note: Pinching the pin on one end will help when installing the pin. Slide the brake drum-spur gear adapter (BMSP097) over the shaft, making sure the slot in the back of the drum is aligned with pin. Use the 5mm lock nut (HDWR-013) to secure the drum (Fig. 26). Place the 4-40 x 5/8" FHCSC screw (HDWR-008) thru the brake shoe (BMSP098) and thru the bottom hole on the right side tranny plate. Screw the 4-40 locknut (HDWR-010) on the screw on the other side of the plate. Tighten the locknut and back it off just enough to let the shoe move free (Fig. 27).

     

         Fig. 25                                                            Fig. 26                                                  Fig. 27

Your belt drive transmission is complete.

(Sprint Car Only)

Step 1: The parts needed for this step will be the left side cage(BMSP012), the right side cage (BMSP013), 2 cross members (BMSP040), (6) #4 washers (HDWR-032), (2) 4-40 x 3/4" SHCSC (HDWR-020A), (2) 4-40 x 3/4" SHCSC (BMSP-020), and (4) #4 x 1/8" spacer. Assemble the wing mount screws as shown in figure 1. The (2) 3/4" SHCSC (HDWR-020A) cross-drilled screws have the spacer sandwiched by washers.

  

          Fig. 1                                                                  Fig. 2 Rear of Cage

Step 2: Place the (2) screw assemblies with out the hole in the front cross member and the (2) with the hole in the rear as shown in figure 2.

Step 3: Fasten the support (BMSP016) to the rear nerf bar (BMSP017) using a 4-40x½ SHCSC (HDWR-017) as shown in Fig. 3. Now you will fasten the rear nerf bar and support to the cage sides. See Fig. 4

  

        Fig. 3                                                  Fig. 4

Set assembled cage aside for now.

Step 4: Assemble the body side panels (BMSP030) together using (4) 2-56 x 1/4 BHCSC (HDWR-022), and (4) #2 washers. Install the left (BMSP014) and right nerf bars (BMSP015) on the side panels using (2) 4-40 x 3/16 SHCSC (HDWR-026). See Fig. 5-6.

Note: Left nerf bar is marked with tape. NOTE: Remove the protective covering from the side panels before painting.

     

Fig. 5                                                                              Fig. 6

Step 5: Assemble the wing using 4-40 x 5/16 BHCSC(HDWR-003) and 4-40 locknuts (HDWR-010) as shown in Fig 7.

Fig. 7

Step 6: The wickerbill holes will need to drilled into the wing sides. Set the wickerbill at approximately 45 degrees and drill the holes in the side panels as shown in figure 8 and 9.

     

         Fig. 8                                                            Fig. 9                                                              Fig. 10

Step 7: Drill (6) 1/8" holes in the wing deck(BMSP027). Find the center of the deck at each end and place a line. Measure off of the center line 1.875" and place another line the length of the deck. Measure in from the front of the wing .875" and place another line intersecting the two vertical lines. From that line measure back 1.75" and place another line intersecting the vertical lines, and again 1.75" from the last mark. See Figure 10.

Step 8: Now you will assemble the wing mounts using 4-40 x 5/16 BHCSC(HDWR-003) and 4-40 locknuts (HDWR-010). See figure 11.

 

Fig. 11