Help me build an aluminium racing toboggan....
Discussion
eliot said:
Just found this one:
http://cgi.ebay.co.uk/Aluminium-sledge-/1404837856...
By cracky. http://cgi.ebay.co.uk/Aluminium-sledge-/1404837856...
I totted up the total costs of the Mk3, main runners (and offcuts used to make the uprights) was £11.50. Crossmembers were offcuts, but using 1" tube instead (lighter and cheaper), would have cost around £1 for both. And £5 for the two side poles.
So the Mk3 comes in at around £20 materials cost including a cordura seat.
And around 3-4 hours welding, shaping, and painting....
I've thought about the costs of making a lot, and it's interesting. Sending the runners off to a specialist to be bent to a perfect shape would actually work out quite inexpensive per unit, and the side pieces likewise. The Mk3 would certainly be the easiest to mass product by a long way, there's little difficulty in any of the joins or structure like the other two.
I would guess a pro could weld it together (assuming it was in a good, sturdy jig, and not on an old ikea table with some MDF on top) in less than an hour, possibly 30 minutes.
Anyway, I've got a Mk4 on the way, we'll be testing in the alps (for fun only) in February, and I might look in to making some for next Christmas.
Pitch at the higher quality, custom made end of the market, optional carbon fibre seat, etc. It would come in cheaper than the 'Porsche' version, and look much better too.
Interesting....
CaptainSlow said:
maser_spyder said:
CaptainSlow said:
It is interesting, I'm thinking a sell-out of about £100-£120 with a retail of £199 or maybe £249?
For Mk1, 2 or 3? 
In fact, a Mk2 or similar could be achievable for £199-ish, as it's a much simpler design to make.
The Mk1 has a LOT of welding in it, and a lot of difficult curves, and tube-to-tube welding, making it very confusing.
I really should have started with the Mk3 first (easy), and got harder, but typical bloke, I went about it completely arse about face and started with the most difficult, and have made them simpler as I've gone on.
The first one was actually learning to weld, so it would be a LOT better now. If there's time, I'll knock up another one to see if I can do it better.
Glad I've inspired some of you lot to give it a go, it's great fun!
A little bit of making the seat for the Mk3 last night....
Big sheet of cordura - £6 on ebay.
Laid the Mk3 on the floor and cut around the basic seat shape (that's the square cut out, not where it is in the piccy
).
Then stitched around it with my fantastic new sewing skills, I'll be putting in the eyelets tonight with my £4.99-from-maplins-eyelet-tool.
A bit of webbing (old seat belts) to add some extra support, and lay the seat over the top, and rope in to place around the edges, done.
This is the 'idiots' Toboggoff, so will be painted the nice shade of pink as per the bottom crossmember.
Big sheet of cordura - £6 on ebay.
Laid the Mk3 on the floor and cut around the basic seat shape (that's the square cut out, not where it is in the piccy
).Then stitched around it with my fantastic new sewing skills, I'll be putting in the eyelets tonight with my £4.99-from-maplins-eyelet-tool.
A bit of webbing (old seat belts) to add some extra support, and lay the seat over the top, and rope in to place around the edges, done.
This is the 'idiots' Toboggoff, so will be painted the nice shade of pink as per the bottom crossmember.
Nearly the last update for the Mk3, it just needs painting and a few bits tickled up like some strapping around the front poles, some padding on the rear crossmember, and it's complete.
I test fitted the seat, just to make sure it'll fit OK once the paint is dry, and actually, it doesn't need webbing underneath, it's better to sink down in to it. It needs some padding on the back though, it's a little hard to lean back on!
And finally, test fitted the video camera, which fits perfectly, but will need to be a bit more stuck in place, or I can see us losing it!
Just off to do some painting now, it's too cold to be in the workshop rubbing down the seat.
I test fitted the seat, just to make sure it'll fit OK once the paint is dry, and actually, it doesn't need webbing underneath, it's better to sink down in to it. It needs some padding on the back though, it's a little hard to lean back on!
And finally, test fitted the video camera, which fits perfectly, but will need to be a bit more stuck in place, or I can see us losing it!
Just off to do some painting now, it's too cold to be in the workshop rubbing down the seat.
LivingTheDream said:
maser_spyder][rant]PINK PAINT[/rant said:
It's not going to be pink any more.
Any colour suggestions for Mk3 please?
A nice base colour, plus some graphics that I'll do in vinyl, before a coat of lacquer.
Just paint to do and it's pretty much finished.
Really nice work Maser - very impressed.Any colour suggestions for Mk3 please?
A nice base colour, plus some graphics that I'll do in vinyl, before a coat of lacquer.
Just paint to do and it's pretty much finished.
I'd go for British Racing Green with yellow decals and a white roundel with the number 3 (or Mk3) in it. Although not sure where you fit the roundel.
Harks back to the early F1 cars driven by Stirling Moss et al.
Perfect for a British made racer with a Pistonheads theme
British made
Thanks for that, you've given me some inspiration.... Watch this space.
shirt said:
stick with pink and add a 'powered by fairydust' decal
Would have been brilliant, the idea was, it was the backup toboggoff, only to be used when yours broke...Problem is, it looks a bit better than a toboggan should that's made of offcuts, so it's hardly a penalty, and also, the pink paint was a right bugger to use. Really thin, and ideally needed a very light coloured primer. I did four coats, got nowhere, so gave up!
Goochie said:
Have you considered widening the skis? It would make it more useable on deep snow and possible allow you to go faster in all conditions without it digging in too much.
Could be easily tested with a bolt-on retro fit for one of the current designs.
Yes, I thought that, but we'll be using 'prepared' toboggan runs, so I don't think it'll be an issue. Most toboggans have 1" runners, the sport ones slightly wider. My runners are 1 1/2", so already a little larger than most.Could be easily tested with a bolt-on retro fit for one of the current designs.
I did actually buy some 1" square to make a toboggan with thinner runners, which I ended up never using.
Actually, I've still got it. This might be a Mk5 coming on....
Bill said:
Why have you left the front seat rails sticking out? (You could have someone's eye out etc )
They need cutting back a little bit, I just haven't gotten around to it yet. It's normal for them to stick out very slightly though. I've no idea why, but it's normal! )Although, flying down a hill on a home-made, welded-by-an-amateur toboggan, with ultra slippery PE runners, probably after a couple of beers, my, or anybody else's eyes, are really the last thing to worry about.
I also forgot to mention....
We'll be in Kitzbuhel, Austria, for all of February and March next year, trying out all the local toboggan courses in the area.
If there are any PHers heading out this way, drop me a PM and you're more than welcome to come along and 'test' any of these models!
We'll be in Kitzbuhel, Austria, for all of February and March next year, trying out all the local toboggan courses in the area.
If there are any PHers heading out this way, drop me a PM and you're more than welcome to come along and 'test' any of these models!
Done, pics back!
Tonight, (Matthew), I have been painting the mk3 dark green, and designing the graphics for the first three models. It's too damned cold to be at the workshop sanding the seat.
Will be printing/cutting tomorrow with a bit of luck, so applying graphics to the mk1 and 3 this weekend. Then they'll really start to look finished.
I have a mini dv cam for each toboggan, so there will be plenty of footage for YouTube!
Tonight, (Matthew), I have been painting the mk3 dark green, and designing the graphics for the first three models. It's too damned cold to be at the workshop sanding the seat.
Will be printing/cutting tomorrow with a bit of luck, so applying graphics to the mk1 and 3 this weekend. Then they'll really start to look finished.
I have a mini dv cam for each toboggan, so there will be plenty of footage for YouTube!
LivingTheDream said:
maser_spyder][rant]PINK PAINT[/rant said:
It's not going to be pink any more.
Any colour suggestions for Mk3 please?
A nice base colour, plus some graphics that I'll do in vinyl, before a coat of lacquer.
Just paint to do and it's pretty much finished.
Really nice work Maser - very impressed.Any colour suggestions for Mk3 please?
A nice base colour, plus some graphics that I'll do in vinyl, before a coat of lacquer.
Just paint to do and it's pretty much finished.
I'd go for British Racing Green with yellow decals and a white roundel with the number 3 (or Mk3) in it. Although not sure where you fit the roundel.
Harks back to the early F1 cars driven by Stirling Moss et al.
Perfect for a British made racer with a Pistonheads theme
British made
I've ordered some webbing to make the strap and front pole strap, which will be riveted in to place, then it really is very nearly finished,
Mk2 has also been painted tonight, bright red, that looks great too.
I've got two more ideas left, and only one set of runners (and only limited room in the truck on the trip out), so the mk4 is going to be the best yet. Watch this space, I'm going very technical with the last one....
Pics as promised!
Unfortunately, the lacquer reacted a little with the paint (no idea why), and there's a couple of crackled bits that need flatting off with 1000/1200 and re-lacquering. Not a major job, but I've got this far, so may as well finish it properly.
Just waiting for the webbing to arrive now so that I can get the strap riveted in. I also need to cut back the front poles slightly, but my angle grinder has given up (needs brushes), so need to get a new one.
The decals were cut on the vinyl printer/cutter we have in the office, I had some rolls of vinyl that were thrown in with a printer I bought a couple of years ago, luckily there was plenty of yellow/gold/red to do strips, etc.
I did plenty of spares, just in case!
Applying vinyl is pretty easy, in this case, I did it by hand rather than with transfer paper (apart from the lettering, which was done by using transfer paper), and lined up the stripes by eye. If they're a little out, then it's my eyesight to blame.
So, here's the Mk3, painted, and ready for stickers.
And applying them, you can see I did a few different thicknesses of strips, just to give me some options. It was all designed on the hop, almost no planning here!
And the final article, just needs flatting off, another coat of lacquer, and re-fit the seat and webbing strap.
I'm being dragged out Christmas shopping this afternoon, but will try to start work on Mk4, and finish the seats for Mk 1 and 2 on Sunday.
Unfortunately, the lacquer reacted a little with the paint (no idea why), and there's a couple of crackled bits that need flatting off with 1000/1200 and re-lacquering. Not a major job, but I've got this far, so may as well finish it properly.
Just waiting for the webbing to arrive now so that I can get the strap riveted in. I also need to cut back the front poles slightly, but my angle grinder has given up (needs brushes), so need to get a new one.
The decals were cut on the vinyl printer/cutter we have in the office, I had some rolls of vinyl that were thrown in with a printer I bought a couple of years ago, luckily there was plenty of yellow/gold/red to do strips, etc.
I did plenty of spares, just in case!
Applying vinyl is pretty easy, in this case, I did it by hand rather than with transfer paper (apart from the lettering, which was done by using transfer paper), and lined up the stripes by eye. If they're a little out, then it's my eyesight to blame.
So, here's the Mk3, painted, and ready for stickers.
And applying them, you can see I did a few different thicknesses of strips, just to give me some options. It was all designed on the hop, almost no planning here!
And the final article, just needs flatting off, another coat of lacquer, and re-fit the seat and webbing strap.
I'm being dragged out Christmas shopping this afternoon, but will try to start work on Mk4, and finish the seats for Mk 1 and 2 on Sunday.
Or888t said:
Just read the entire thread in one sitting,
Absolutely-Awesome!!!
Top work!
Really great read, very inspiring.
&Really looking forward to -many- more updates!
p.s There is certainly some commercial viability in all of this, You should start thinking of them as prototypes!
Absolutely-Awesome!!!
Top work!
Really great read, very inspiring.
&Really looking forward to -many- more updates!
p.s There is certainly some commercial viability in all of this, You should start thinking of them as prototypes!
Cheers!It's been great fun, I wholly recommend it!
And I have mentioned it to my staff in China, who are looking in to aluminium fabricating factories....
CharlesdeGaulle said:
Maser. Just wanted to say that I have watched this absorbing and inspiring thread with real interest. You have made a terrific job of it (them!), well done.
What especially tickled me was the delightfully Heath-Robinson-ish approach to doing something for the first time. A real case of adapt and overcome - most impressive and thanks for sharing. I look forward to the real-life performance stats.
Cheers!What especially tickled me was the delightfully Heath-Robinson-ish approach to doing something for the first time. A real case of adapt and overcome - most impressive and thanks for sharing. I look forward to the real-life performance stats.
It's been absolutely great fun so far, and I still have the seats and finishing off to do.
And the mk4 and possibly 5 are still to come.
I have big plans for mk4, now that I have a bit of experience in the fabricating line, I'm being a little more ambitious for the last one. A lot of thinking has gone on so far, but no actual work as yet!
PE strips have arrived, so they'll be bolted on some time this week, another finishing touch done.
Watch this space for the last big effort!
RacingPete said:
What are the plans for the front of this one Maser?
As not sure I would want to fall off and have it run into me - Tobogoff Mk3 "The impaler"
Strange isn't it, but that's what they all look like!As not sure I would want to fall off and have it run into me - Tobogoff Mk3 "The impaler"
I'm just waiting for the webbing to arrive, once that's fitted I'll trim them back a little to suit the webbing. They'll probably match the approximate length of the runners.
2 x seats and PE strip fitting this week.
chevy-stu said:
Been coming back to this to read every couple of weeks too, and it's provided great entertainment... Congratulations on what you've achieved.. 
Excellent!maser_spyder said:
I also forgot to mention....
We'll be in Kitzbuhel, Austria, for all of February and March next year, trying out all the local toboggan courses in the area.
If there are any PHers heading out this way, drop me a PM and you're more than welcome to come along and 'test' any of these models!
I'm actually working out in Tirol (Soll, St Anton, St Johann & Landeck) and surrounding areas in Switzerland and Italy for about a week in mid Jan and again for 10 days in late Feb/early March, so may try and meet up to check out the 'Tobogoffs' in action on the slopes.. We'll be in Kitzbuhel, Austria, for all of February and March next year, trying out all the local toboggan courses in the area.
If there are any PHers heading out this way, drop me a PM and you're more than welcome to come along and 'test' any of these models!
Drop me a pm, and I'll give you my mobile number, and you can give me a shout when you're in the area. I'll be in Oz until mid Jan, so not heading out until later in the month.
There's a good, albeit bumpy, toboggan run in Soll, and also a really nice one in Going just up the road. The Kirchberg one is good for night runs. I've also been reading about one I didn't know about, on the road up to Pass Thurn, no doubt we'll have that tried and tested by late Feb....
Edited by maser_spyder on Monday 6th December 19:26
Du1point8 said:
Dont suppose you would mind putting up some design plans and what materials where used for the toboggans (all 3) as I would like to make one or 2 of them in Finland over next summer ready for next winter there... dont have the time this winter due to a trip to LapLand to sort them out.
Or are you going to turn this into your own business idea?
They're all a little different in terms of materials, but if you let me know which one you like, I'm happy to tell you what went in to it.Or are you going to turn this into your own business idea?
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