Toylander from scratch (metal chassis and body)

Toylander from scratch (metal chassis and body)

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Hard-Drive

4,076 posts

228 months

Wednesday 12th January 2022
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cobain said:
Great work, really interesting to see. I have seen another fabricated one somewhere certainly not for the faint hearted.

I have just started accumulating parts for my build, driving to toylander plans mostly but going with a chain drive from a mobility scooter and detailing it where I can.

Hard-drive, love some of the bits you have done with rivets etc. are they real in the MDF.

So far pleased with the steering rack I have sourced and some great side and indicator lights.



Those lights are great. What's the supplier?

cobain

51 posts

162 months

Wednesday 12th January 2022
quotequote all
Really pleased with them, hopefully the below works:

FIAT SEICENTO 1999-2004 MULTIPLA 1998-2009 SIDE INDICATOR AMBER - PAIR

https://www.ebay.co.uk/itm/FIAT-SEICENTO-1999-2004...

They come in clear and amber, I need to experiment to make a red pair for the rear. Thinking a vinyl wrap. The mobility scooter has a “brake light” that comes on when you lift off the power and stays on for 5 secs once you stop. I’ve had an idea to use one bulb for tail and stop…..the mobility brake light is 24v so if I use a 24v bulb with a 12v feed for tail it will then get brighter when the 24v brake light kicks in, maybe!

If you could let me know the secret behind your rivets in MDF that would be much appreciated!

InitialDave

11,853 posts

118 months

Wednesday 12th January 2022
quotequote all
cobain said:
They come in clear and amber, I need to experiment to make a red pair for the rear.
https://www.ebay.co.uk/itm/353408019497

Hard-Drive

4,076 posts

228 months

Wednesday 12th January 2022
quotequote all
cobain said:
Really pleased with them, hopefully the below works:

FIAT SEICENTO 1999-2004 MULTIPLA 1998-2009 SIDE INDICATOR AMBER - PAIR

https://www.ebay.co.uk/itm/FIAT-SEICENTO-1999-2004...

They come in clear and amber, I need to experiment to make a red pair for the rear. Thinking a vinyl wrap. The mobility scooter has a “brake light” that comes on when you lift off the power and stays on for 5 secs once you stop. I’ve had an idea to use one bulb for tail and stop…..the mobility brake light is 24v so if I use a 24v bulb with a 12v feed for tail it will then get brighter when the 24v brake light kicks in, maybe!

If you could let me know the secret behind your rivets in MDF that would be much appreciated!
Nice one, thanks.

No secret to the rivets. Just drill a blind hole deep enough for the rivet, put it in the hole and pop it. I will admit to using an air riveter which made everything much quicker! Full thread is here...

https://www.pistonheads.com/gassing/topic.asp?h=0&...



cobain

51 posts

162 months

Wednesday 12th January 2022
quotequote all
I did see that lens tinting spray but it has a few bad reviews for going orange in the sun?

Perfect I wasn’t sure if the mdf would take the rivet without damaging it!

I should have added that I have a series 3 and all of the “details” will be taken from that, capstan winch etc.

Jon, if you need any dimensions (admittedly from a series 3) then just shout. Looking forward to seeing progress I do a bit of laser cutting and fabrication so will offer advice where I can!


Jon_Bmw

Original Poster:

619 posts

201 months

Wednesday 12th January 2022
quotequote all
That's a sweet little steering rack! That'll be nice to use I reckon. Those indicators look Bob on as well which is a great find.

I'm using a chain and sprocket setup as well and I think it's quite common. I can send you a link to the supplier of mine if you need, although there are lots of people that do them fairly cheaply.

I had an extremely quick go at practising on the front panel this afternoon. I had 30 mins before I had to pick one of the boys up from nursery, so my efforts were cut short. It was plan A and it's not gone any better or worse than I expected. I'd like some more time with the hammer on Friday to see what can be done.

Many tucks to sort...






Jon_Bmw

Original Poster:

619 posts

201 months

Wednesday 12th January 2022
quotequote all
Tight radius, general inpatientness, 50mm of material trying to lose, lack of skill = picture above. laugh

I need the 50mm as 1/4 circumference is 40m plus 10mm for the flange. I get the feeling if I go down this route I'll be slitting the corner and welding up the gaps after followed by a liberal grinding session.

Jon_Bmw

Original Poster:

619 posts

201 months

Friday 14th January 2022
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So, I'm on plan A+.

Cutting some slits in the metal, forming, then welding up. In hindsight more slits would have been better. The gaps I was having to weld were up to 4mm, which when the panel is 0.8mm thick, is a challenge! I used some odd scrap Aluminium as a backer but it was still unpleasant.











This last photo is fairly damning. Lots of height difference between the welds due to large gaps and a bit of distortion. I'll probably clean up the inside more. Hammer it a bit, grind it back and see what we have got. I think it would need a fair bit of filler in it whatever I do, so I might try plan C next on the other side and see if that goes better.



Considering that's the first metal panel I've ever made, it could be worse, although not quite a success story yet...

cobain

51 posts

162 months

Sunday 16th January 2022
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Certainly not easy to do that panel. Good effort though I think it would be well beyond my talents! Could you use something like your bent piece of pipe and weld a flat panel on to it to make the wing? You would have the pipe radius along the length where the wing side meets the wing top then? And you already have a way to bend the pipe to give the curve where it transitions to the headlight panel? I guess you might then end up taking out the box section you have done already in that area as the pipe would replace it?

Prawo Jazdy

4,944 posts

213 months

Monday 17th January 2022
quotequote all
cobain said:
Really pleased with them, hopefully the below works:

FIAT SEICENTO 1999-2004 MULTIPLA 1998-2009 SIDE INDICATOR AMBER - PAIR

https://www.ebay.co.uk/itm/FIAT-SEICENTO-1999-2004...

They come in clear and amber, I need to experiment to make a red pair for the rear. Thinking a vinyl wrap. The mobility scooter has a “brake light” that comes on when you lift off the power and stays on for 5 secs once you stop. I’ve had an idea to use one bulb for tail and stop…..the mobility brake light is 24v so if I use a 24v bulb with a 12v feed for tail it will then get brighter when the 24v brake light kicks in, maybe!
Please could you tell me what the diameter of the indicator lens is? Such information is obviously too trivial to list on an eBay listing hehe I searched for ages for an indicator which looked right, and I've ended up going with some motorcycle "bullet" lamps made of Chinesium. They're going to be a pain to fit though, and part of the casing will show when they're installed, so I'll have to paint it body colour to mask it, which will reduce the effective diameter.

I can't believe I didn't think of looking at side repeaters! If they're as large or larger than the holes I've cut out, then I'll just get some of those instead. Cheers.

(P.S. If anyone is looking for the clear lamps, they sell them at EuroCarParts for about £1.30 each, instead of £12ish a pair on eBay. Annoyingly I want the amber ones...)
P.P.S. I'm also interested in the steering rack if you are willing to give details of what that is from?
P.P.P.S. I've just realised that cobain isn't the OP - sorry - I'm not trying to derail your thread!

Edited by Prawo Jazdy on Monday 17th January 09:54

cobain

51 posts

162 months

Monday 17th January 2022
quotequote all
Just had a quick measure about 32mm dia.

Painted a pair of clear ones red with Tamiya X-27 clear red which has worked really well.

The steering rack is this one https://www.ebay.co.uk/itm/For-110cc-Go-Kart-Quad-...

I might try and cut it down, slight issue at the moment is that it is central which might make packaging the batteries tricky, long way off that point yet though.

I do need to start my own thread but not much to look at so far and hopefully some of these bits will be handy for Jon

Prawo Jazdy

4,944 posts

213 months

Tuesday 18th January 2022
quotequote all
Thanks! thumbup

Jon_Bmw

Original Poster:

619 posts

201 months

Tuesday 18th January 2022
quotequote all
The comments and suggestions for toylander style parts are most welcome. I see a thread like this as a general information page and how not to do lots of things by yours truly, rather than me being the owner and custodian of it! If its vaguely related, post it up.

I will almost certainly get some of those Fiat bulbs, they look just the trick. As I am a tight arse, I will probably get 6 and see if I can find some orange and red paint lying about...

Ref the panel Cobain, a variation of your suggestion I am planning to try. Having the minimum welding on the panel is key to reduce it warping and distorting I think. Plan C on the previous page is the best bet for me. I do like your idea though. I need to spend a bit of time with the mock up one I had made and the chassis. It is highly likely that my chassis doesn't exactly match the CAD because of the way I made that chassis front section, so it will need tweaking I am sure. I'd rather know what needs tweaking more making an amazing (haha!) panel that doesn't fit the chassis/body.

In other news progress is going to be even more glacial than normal as my garage is now full of OSB and LED light panels so I can board the ceiling and have some proper light in there. It is 40sq metres worth so that will take me ages by the time I have cut them in and fitted appropriate noggins!

Hard-Drive

4,076 posts

228 months

Thursday 20th January 2022
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anonymous said:
[redacted]
Yes, quite right. Steel chassis and bulkhead. Steel door frames, aluminium "Birmabright" skin. And all of the dissimilar metal corrosion issues that go with that!

(says the bloke who just ordered a galvanised bulkhead to fit to his 36 year old Defender...)

Jon_Bmw

Original Poster:

619 posts

201 months

Friday 21st January 2022
quotequote all
Originally I was going to make the body panels out of aluminium mainly to be lighter. Whilst it will form a bit better I still don't think I could do the front arch without welding it. At that point I am stumped, I cannot weld aluminium. The guys I work with can, but I am trying to do as much as I possibly can by myself. Any experience gained here will help with car bodywork in the future. That is how i'm selling it to myself. laugh

If I want to weld wheel arch return lips on this project, that would be fairly straightforward TIG welding (famous last words!) steel. In aluminium its well out of my league.

I'll take the weight penalty of steel and accept the lower cost of the material and the fact I can weld it. I also have found a load of 0.8mm steel sheet metal shelves that are currently ripe for re-purposing!

On the garage front, 3 out of approximately 16 panels done. Painfully slow progress putting up 2.4m OSB on your tod!

cobain

51 posts

162 months

Monday 21st February 2022
quotequote all
Any progress Jon?

I’m still parts gathering at the moment. Using some smiths gauges (2” compared to a 4” Speedo and dial on the landy). Also found some half scale badges on eBay.

Jon_Bmw

Original Poster:

619 posts

201 months

Tuesday 22nd February 2022
quotequote all
The rear axle has been machined but I've not trialed it yet as it's tucked away in the corner until I get more of this roof done!

I'm about half way with the roof is progress is pretty glacial with that as well. Trying to get motivation when it's cold and still dark in there is the issue.

Your gauges look good. I fear nice finishing touches like that will never make it onto mine!

cobain

51 posts

162 months

Saturday 26th February 2022
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Lighter nights should help with that, it’s hard getting anything done in the dark and cold!

Mine is currently all finishing touches and nothing of real substance!

Mirrors in progress, will get them powdercoated black. Waiting for mirror glass to be cut to size.




Jon_Bmw

Original Poster:

619 posts

201 months

Monday 28th February 2022
quotequote all
Cobain, I love the mirror! That is going to look great when painted and the edge protector glued down.

So I contracted Covid, which meant some isolation time.

Half the garage roof and lights done;



Obviously the end I want to work in, hasn't been done rolleyes

My mate from work turned the rear axle. We used 304SS so hopefully it won't rust and even if it does it will still rotate in the pillar bearings. Loosely positioned here.



Some eyeball and some well recognised "to the nearest 5mm measurements" and its bolted down. The pillar bearings even have a grease nipple, Phwooar! Lets be honest, those grease nipple caps aren't coming off in my lifetime. Also you might notice that its going to have about 3/4 of an inch rake between front and rear. If you could be so kind as to not mention it, or else I will tell you I was a redbull engineer and I meant it like that. laugh

The downside of isolation is that you have to use the material at hand, and as most of my material is at work (near the chop saw!) I made do for the motor mount.





Clearance hole for the chain guesstimated, because you guessed it, the chain and motor sprocket is at work too! The angle iron has also been drilled out at 10mm and I will use 4 matching 8mm bolts in time. This allows a reasonable amount of travel in X and Y to set the chain tension and position in Y. Basically to account for many, many build issues! The axle sprocket has been drilled centrally but I haven't cross drilled the axle yet.

The motor has been positioned there so it is hidden (by the drivers bench seat) in the future. I will probably hinge that so I can lock/unlock the motor using the yellow lever.

At that point (about 45 minutes in) I had run out of stuff to do. So, lets make lots of grinding dust and molest the dummy wing some more! I just got a very very loose shape by hand drawing the wheel arch cut out on. This is not the real wing....I repeat, this is not the real wing, until it becomes the real wing due to laziness.

With the radius at the top of the LR wings, the panels are going to be spaced off the chassis by about 1".





When I originally drew the car I hadn't really looked at the shape properly! eek So the front wing on the real thing is like this:



So my plan is to do the following:



The highlighted yellow will disappear. The red will become a new box section. The blue arrow is where I will mount the front bumper. It will help the look and help with ground clearance. You cannot lose, unless you are the poor sod making the changes.

Wing would end up something like this:




Over and out.

eccles

13,720 posts

221 months

Monday 28th February 2022
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I don't mean to be insulting, but your front wings reminds me of Goblin Works Garage for some reason. biggrin