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  #21  
Old September 11th, 2013, 03:25 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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May 2013 - interior placement

Received the hand brake handle today (off a Land Rover Discovery). Looks like the passenger will need to lose some leg room to get it to fit.

I've been thinking about the front grill for a while. I recycled an IKEA-made shoe rack we were going to throw away as well as blind slates to make it.
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I have an ex MoD and an ex wife. The two no longer conflict with each other.
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it is not hoarding it is selective collecting
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1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #22  
Old September 11th, 2013, 03:26 PM
MonLand
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95 D90 - 96 Disco -06 LR3
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May 2013 - License plate

I abused my wife's business trip to get her to bring me back a license plate! Maybe she'll have a trip to the UK sometimes!
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #23  
Old September 11th, 2013, 03:27 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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June 2013 - Drivetrain: change in direction

After researching buying a much strong right angle gearbox or making my own using already-made gears, it became apparent that this would be cost prohibitive! So, change of plans! One of the "recommended" approach is to go with a electric scooter drivetrain for the electric motor setup. After some lengthy search (i.e. many many hours scooting eBay and Craiglist's), I was able to find a "cheap" one! I drove a few hours and picked up an almost-complete $100 electric chair (missing rear caster wheel, no charger, not the greatest seat). Most importantly, it moved on its own!
Kids found this much fun and played with it for almost a week (I could not get myself to stop them from doing this). Amazingly enough, batteries that came with it seem to even hold charge!
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Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #24  
Old September 11th, 2013, 03:29 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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June 2013 - Body work

Got some time to work on the bonnet and the front grill. Bonnet still need more work (more sanding, attach a small piece of wood on the front fitting the hinges, etc) but this is turning ok! Front grill needs to be glued now that it seems to look like I think I want it to look like and how it "integrates" with the bonnet.
This is a picture where most of the front end is somehow hanging on the front of the Lil'Defender (read: nothing is screwed or glued! ).
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #25  
Old September 11th, 2013, 03:30 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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July 2013 - Drivetrain work

I took the Jazzy mobility chair apart and extracted all the drivetrain components. The chair has a direct drive system where the motor, reduction gearbox and wheels are attached directly to each other. I need this changed so I can adjust the speed due to the tire size change (from 12" to 16") -and- my rear axle sits much lower than where the motors are supposed to be attached!

Pictures of the motor setup inside the Lil'Defender.
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #26  
Old September 11th, 2013, 03:32 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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July 2013 - Axle pictures

Just for documentation purpose, here are closeups of the front and rear axle setup (Front axle will need to get modified at a later time for the 4x4 setup; current setup will not work/ lawnmower gearbox is too weak and can not handle the torque I have already verified that...).
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #27  
Old September 11th, 2013, 03:35 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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August 2013 - Front lights

I think I found the right light combination! Looks similar to what it is supposed to mimic!
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #28  
Old September 11th, 2013, 03:36 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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August 2013 - Body almost complete

Historical moment! Yesterday, I cut what I think is the last piece of MDF I will need to cut to complete the body: rear upper wings. I also started using wood filler to get closer to the "ready for painting" step. Purchased some sealer/primer that I tried on the front grill.... Hum... Does not seem like it is penetrating into the wood.... Seems to work great as a primer though... I might just go to use diluted PVA instead (like most folks here seem to be using).

I installed some front axle swing limiting devices (aka "bolts") until I figure out how to make that better.
As I was ready to do the axle modification I was -thinking- there is a way to put those bolts on the rod that attaches to the steering knuckles and have some plate attached to the body with the right shapes to allow axle swinging more or less based on steering position... Hum.... Too much thinking not enough doing!
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #29  
Old September 11th, 2013, 03:38 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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September 2013 - Steering box installed

A few months ago it was apparent that the direct steering setup I made was way too hard for kids to use. I could barely turn the wheel myself! After checking what adjustment I could do, a new design seem to the only way out.
So, I started working on the steering a few weeks ago. The main challenge for me was to find a way to keep is as compact as possible so I would not compromise space under the battery box. I still plan on using that space to run belts for the front transmission.
The plan was a sprocket-based setup like it was described on some forum posts here. Finding a small sprocket was surprisingly easy. The smallest combination that gives roughly a 1:3 ratio was 9- and 28-tooth sprockets. The 9-tooth has a 1/4" bore.
First attempt for the setup involved 1/4" bolts. This fitted perfectly the 1/4" bore. But.... Doing a few left-right right-left just broke the bolt. Apparently, the steering needs the full 1/4" of solid metal. Received the needed hardware this week and got a chance to put the box back together with it. While there is still no real testing done, at least the box gets turning a few times. This definitely look like a weak spot in my design that will likely need attention once the kids get the lil'Def in their hands....
A few pictures of the setup.
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #30  
Old September 11th, 2013, 03:41 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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2013 August: finally drew what the 4x4 setup will look like

Original design (using the same lawnmower reduction/transmission box than for the rear) did not work out. New design will be slightly simpler if it works! Here are some diagram I hope will help get feedback before I run into another wall and have to start over.

This is the thread on the Toylander forum: http://www.toylanderownersclub.com/f...3.html#msg8423
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__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #31  
Old September 11th, 2013, 03:44 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Quote:
Originally Posted by evilfij View Post
It would have been cheaper and easier to buy the kids a disco I!
You can easily buy two D1 for the cost of material..... I'm not even factoring the time.....
If someone ever ask me: don't do it! Or just go ahead and send your dollars to the UK to buy a complete kit. Custom is way too much time/money/effort/tears/blood/etc.
__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #32  
Old September 11th, 2013, 03:51 PM
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rijosho
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Joshua
1995 Black ST - Rhinolined edition
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Quote:
Originally Posted by MonLand View Post
After researching buying a much strong right angle gearbox or making my own using already-made gears, it became apparent that this would be cost prohibitive! So, change of plans! One of the "recommended" approach is to go with a electric scooter drivetrain for the electric motor setup. After some lengthy search (i.e. many many hours scooting eBay and Craiglist's), I was able to find a "cheap" one! I drove a few hours and picked up an almost-complete $100 electric chair (missing rear caster wheel, no charger, not the greatest seat). Most importantly, it moved on its own!
Kids found this much fun and played with it for almost a week (I could not get myself to stop them from doing this). Amazingly enough, batteries that came with it seem to even hold charge!
Wow great job so far! Those kids sure do grow up quickly! They were so much smaller just a few years ago at MAR playing with my dog.
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I am talking purely from an aesthetics standpoint.
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  #33  
Old September 11th, 2013, 04:04 PM
MonLand
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Loic Fabro
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Quote:
Originally Posted by rijosho View Post
Those kids sure do grow up quickly! They were so much smaller just a few years ago at MAR playing with my dog.
Hum.... So the rumor is true.... You DO have a file on every Land Rover owner????

Yes, it's crazy how fast they grow up! So fast that soon they'll be too big to ride in the Lil'Defender.... I've got to hurry up!
__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #34  
Old September 11th, 2013, 04:04 PM
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Steve Maietta
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Get it done quick or the kids wont fit!!!

nice work. How about using a couple coats of polyurethane as the MDF sealer? I know that stuff gets destroyed really fast once it gets wet, the poly should soak in and really waterproof it.
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  #35  
Old September 11th, 2013, 04:20 PM
MonLand
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Sealer: what to do?

Quote:
Originally Posted by revtor View Post
How about using a couple coats of polyurethane as the MDF sealer? I know that stuff gets destroyed really fast once it gets wet, the poly should soak in and really waterproof it.
So... That's been my dilemma for the past few weeks. I can't seem to get a straight answer on how to best -seal- the MDF. The one I used is "moisture resistant" which means "slightly better than standard MDF".
It's my first time working with MDF and most people using MDF using it for interior stuff. Some folks are using it for signs (i.e. one piece of MDF).

I need to find something that seals the MDF by going "deep" into it, without removing/reacting with the glue that was used to make it in the first place. Something that will stay "flexible" to so it will handle the expansion/contraction that will happen to the body. And of course, I want to be able to paint the top coats with some oil-based finish (enamel spray paint likely)

I bought primer (I used on the front grill) but it does not seem to go into the wood fibers at all (even though the can says "sealer" as well....).

I'm not sure about polyurethane. It seemed like a great option to me. I mean.... You can dump water on a wood floor and not worry about it right? I could not find anything on the cans I looked at that said "good for exterior use". Any experience with this outside?

Shellac would not work for an exterior application because it does not expand/contract (and would show cracks).

I would like to stay away from anything water-based since it seems to not be able to penetrate the MDF much.
At the moment, I think I will go with a oil-based "sanding primer" ("sanding sealer"?).

The Toylander folks seem to use PVA-glue watered down. That seems ok to me except it's water-based and apparently requires a lot of sanding as it raises the grain. And while this seem the almost cheapest option.... I'd hate to see so many hours wasted due to an extra $20 I did not spend. So I want to think there is a better option. Maybe I should go to a paint store and talk to a professional!

p.s.: so glad I posted this here.... So much more feedback than on the Toylander forums! I do exist here!
__________________
Quote:
I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
---
MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #36  
Old September 11th, 2013, 04:24 PM
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Charles Galpin
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Sweet, it's a one link suspension!
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  #37  
Old September 11th, 2013, 04:40 PM
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thomas
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Quote:
Originally Posted by MonLand View Post

So... That's been my dilemma for the past few weeks. I can't seem to get a straight answer on how to best -seal- the MDF. The one I used is "moisture resistant" which means "slightly better than standard MDF".
It's my first time working with MDF and most people using MDF using it for interior stuff. Some folks are using it for signs (i.e. one piece of MDF).

I need to find something that seals the MDF by going "deep" into it, without removing/reacting with the glue that was used to make it in the first place. Something that will stay "flexible" to so it will handle the expansion/contraction that will happen to the body. And of course, I want to be able to paint the top coats with some oil-based finish (enamel spray paint likely)

I bought primer (I used on the front grill) but it does not seem to go into the wood fibers at all (even though the can says "sealer" as well....).

I'm not sure about polyurethane. It seemed like a great option to me. I mean.... You can dump water on a wood floor and not worry about it right? I could not find anything on the cans I looked at that said "good for exterior use". Any experience with this outside?

Shellac would not work for an exterior application because it does not expand/contract (and would show cracks).

I would like to stay away from anything water-based since it seems to not be able to penetrate the MDF much.
At the moment, I think I will go with a oil-based "sanding primer" ("sanding sealer"?).

The Toylander folks seem to use PVA-glue watered down. That seems ok to me except it's water-based and apparently requires a lot of sanding as it raises the grain. And while this seem the almost cheapest option.... I'd hate to see so many hours wasted due to an extra $20 I did not spend. So I want to think there is a better option. Maybe I should go to a paint store and talk to a professional!

p.s.: so glad I posted this here.... So much more feedback than on the Toylander forums! I do exist here!
I have worked with water resistant MDF. Take a scrap piece and throw it in a mason jar with water before you do anything and see what you are working with. Look up a "architectural wood worker in you are and see what paints he recommends. Most high end paint grade woodworking is being done in MDF now. A couple weeks ago I was working with 2 inch thickness 16' MDF panels....
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  #38  
Old September 12th, 2013, 02:31 PM
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Steve Maietta
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polyurethane is waterprof and will soak into the wood. you're not planning on leaving it outside are you? I think 2-3 coats with light sanding in between should seal it well enough espeicially if you're going to paint it afterwards.

have fun!!!!

~Steve
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  #39  
Old September 12th, 2013, 02:41 PM
slorocco
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Dan Prasada-Rao
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If you look up the CLC kayak folks, they're building kayaks out of marine plywood. The use epoxy and then a paint or varnish.

Quote:
Originally Posted by MonLand View Post
So... That's been my dilemma for the past few weeks. I can't seem to get a straight answer on how to best -seal- the MDF. The one I used is "moisture resistant" which means "slightly better than standard MDF".
It's my first time working with MDF and most people using MDF using it for interior stuff. Some folks are using it for signs (i.e. one piece of MDF).

I need to find something that seals the MDF by going "deep" into it, without removing/reacting with the glue that was used to make it in the first place. Something that will stay "flexible" to so it will handle the expansion/contraction that will happen to the body. And of course, I want to be able to paint the top coats with some oil-based finish (enamel spray paint likely)

I bought primer (I used on the front grill) but it does not seem to go into the wood fibers at all (even though the can says "sealer" as well....).

I'm not sure about polyurethane. It seemed like a great option to me. I mean.... You can dump water on a wood floor and not worry about it right? I could not find anything on the cans I looked at that said "good for exterior use". Any experience with this outside?

Shellac would not work for an exterior application because it does not expand/contract (and would show cracks).

I would like to stay away from anything water-based since it seems to not be able to penetrate the MDF much.
At the moment, I think I will go with a oil-based "sanding primer" ("sanding sealer"?).

The Toylander folks seem to use PVA-glue watered down. That seems ok to me except it's water-based and apparently requires a lot of sanding as it raises the grain. And while this seem the almost cheapest option.... I'd hate to see so many hours wasted due to an extra $20 I did not spend. So I want to think there is a better option. Maybe I should go to a paint store and talk to a professional!

p.s.: so glad I posted this here.... So much more feedback than on the Toylander forums! I do exist here!
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  #40  
Old September 12th, 2013, 03:32 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Quote:
Originally Posted by revtor View Post
polyurethane is waterprof and will soak into the wood. you're not planning on leaving it outside are you? I think 2-3 coats with light sanding in between should seal it well enough espeicially if you're going to paint it afterwards.

have fun!!!!

~Steve
Not "planning" on leaving it outside (garage does not have heating or A/C though! ) but planning on making it go through some mud/water just like an std LR would (-if- that's possible of course! ).
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I have an ex MoD and an ex wife. The two no longer conflict with each other.
Quote:
it is not hoarding it is selective collecting
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1996 Discovery NAS
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