Instructions – Foamblock

Project Zephyr - Mini

This is our special private instruction page - if you are here, you have received an invitation to join Project Zephyr, or you are a friend. We hope you enjoy this mini model.

We made this to showcase our ability to produce awesome products while giving you a tase of what your experience with Project Zephyr will be like when you decide to start the journey.

Should you have any questions about assembling the car, or if you encounter any issues these instructions don't cover - please do not hesitate to call - contact details are in the box.

All 3D printed parts are made of biodegradable and bio-sourced PLA. Black components are made from recycled PLA. 99% of our custom made packaging can be recycled or upcycled as storage if it didn't get damaged during transport.

Some tips before you begin:

1.Magnets hold all parts together and may require some gentle wiggling to click in place - Your car was fully assembled before packaging and disassembled into your gift box to ensure everything fits.

2.Some parts are quite fragile - however, nothing a drop of superglue can't fix if too much force is accidentally applied.

3.In case a magnet is pulled out - find the part it's supposed to stick to and glue it back in with a drop of superglue, ensuring the correct polarity is maintained.

4.Open all the layers inside the box before you begin - some parts are at the bottom.

5.Ensure you rub off the glue used to hold the parts in place for safe transport.

Add the stainless steel sheet - Large cutout rectangle to the right.

Add the rear axles - Ensure you slot the disk break and rear pulley into the square slots in the stainless steel sheet first.

Add the roll cage structure - It comes in 3 parts. 2 arms in the front and one 6 legged frame in the back. It clicks across the stainless steel sheet and sandwiches it to the base frame. Wiggle the car and the components a little to straighten everything out after this step.

Add the outer structure - It comes in 4 parts. Front, Rear, and two side arms.

Ensure the side arms have the magnet facing outwards and the bend towards the front of the car.

Add the wheels and straighten everything out once again.

Add the body structure using the small magnets wrapped in tape.
This part requires some wiggling to get right. Start from the back and work your way to the front.

Tip: Separate the small 2x1mm magnets from your stack one by one and drop them from about 1-2cm while holding the paper. Its polarity will align as it flips in the air while zooming to the magnet on the car frame.

Ensure the magnet holds the tippy tips of these two paper parts.