While I never expected that the kit for Canopus would be easy to put together, I hadn't expected to hit quite so many issues as I have so far. Prior to this post I had used six etched parts, one of which I broke and one of which I destroyed and had to replace. Rather foolishly I hoped that the next step would go together easier.
Having assembled the cab the next stage involves fitting the smokebox, boiler and saddletank. This actually involves four parts as the boiler consists of a brass tube and a cast whitemetal weight. The other two parts are also whitemetal castings (the kit includes both a cast and etched saddletank but I'm using the cast version as it is heavier). The bottom of the smokebox needs a hole drilling and tapping to take the other fixing screw (the first one is at the bottom of the coal bunker) that keeps the body attached to the chassis. This was easy to do as there is a dimple in the casting to aid correct positioning. Having test fitted the smokebox to the footplate I found that the boiler wouldn't fit.
The problem, as you can see from the first two photos is that while the instructions say that the saddletank "should be a snug fit against the cab ... so that it just touches the smokebox" both the boiler tube and weight are longer than the saddletank casting. The solution is easy, although rather time consuming.
First I used a razor saw in a small miter box to trim the brass tube to a more acceptable length, before then filing it to an exact match to the length of the saddletank. I then filed the whitemetal weight down until it was the same length as the brass tube. Having test fitted the parts they do fit although I haven't yet had the time to actually glue and solder everything into place so that will (hopefully) be a job for tomorrow.