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  #1  
Old September 11th, 2013, 02:52 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Location: Herndon, VA - USA
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NAS Toylander build

This thread is pretty much a mirror of the one I have running on the Toylander forum. But I figured some of you might want to cheer me up/give me a hand at times!

Toylander build thread: http://www.toylanderownersclub.com/f...ic,1148.0.html

This is the build thread for my Toylander 2-based Land Rover Defender 90 NAS (North American Specifications). Of course, I meant "for my kid's TL2...."!

Since I've been working on it for so long, I figured it'd be good to get some of that stuff out so others can learn from my mist... err.... experience! At times, I wished I had listen to you guys....

Anyway, what's specific to the D90 NAS? Not much! Clues are mostly visual:
- external roll cage (that I do not plan on having in my build, but who knows)
- signal lights are different than standard models (turn signals front and rear, backup light and stop lights)
- rear step bumper
- tire carrier
- numbered plaque at the rear right side

What will be more specific to my build:
- should look like my NAS D90 (I have a black soft top truck with 33" tires)
- trying to get the Lil'Defender to work the same as a real one: 4x4, live front axle, multiple speeds, signals/horn/light switch attached to the steering wheel, hand brake
- should include (as much as possible) real Land Rover parts (that is a hard part! So far I only have two genuine parts that fit the build....).
- use fender extensions/flares just like defender do (and to cover the wide tires)

Will soon post pictures of the various steps of the build.

------ Follow up post added September 11th, 2013 02:53 PM ------

That's a lot of stamps!
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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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MonLand
1995 D90 NAS
1996 Discovery NAS
2006 LR3 NAS (hers, but comfy! :) )
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  #2  
Old September 11th, 2013, 02:54 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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March 2012: the beginnings

That's a lot of stamps!
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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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  #3  
Old September 11th, 2013, 02:57 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
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April 2012: first cut

After a bunch of phone calls, I was able to special order 2 sheets of moisture resistant MDF!

Time to make the first cut!
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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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  #4  
Old September 11th, 2013, 02:58 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
Posts: 1,642
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April 2012 - driveline "planning"

The plan is to use two 24V electric motors (for a Razor Scooter), a lawnmower gearbox (front wheel-drive kind) and a few sprockets. Looking good when laid out on the floor! Except that the body is not even close to be assembled and I have no idea if the whole thing will fit....
Sourced wheel online for cheap. I hope they won't be too big neither. I mean.... Wheel can never be too big, can they?
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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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  #5  
Old September 11th, 2013, 02:59 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
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April 2012 - side panel could be the give-away!

Kids have seen me less and less.... They are starting to ask question on what's going on. This ONE panel needs to go in hiding I think if I don't want the whole secret thing to become public....
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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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  #6  
Old September 11th, 2013, 03:01 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
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April 2012 - First Defender specific modification

The Rear cross member of the Toylander 2 needs to be modified to look more like a Defender (from a Series II look). This is the first Defender-specific modification. I can handle that one!
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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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  #7  
Old September 11th, 2013, 03:02 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
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Posts: 1,642
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April 2012 - panel assembly

Well... that was a lot of cutting, let's do some screwing around now!
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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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  #8  
Old September 11th, 2013, 03:04 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
Posts: 1,642
Registry
May 2012 - gearbox parts have arrived! :)

Sprockets and bearings showed up in the mail today!
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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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  #9  
Old September 11th, 2013, 03:04 PM
The Dro
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Dro
1988 Ninety
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Impressive work dood.
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  #10  
Old September 11th, 2013, 03:06 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
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May 2012 - Front axle work

Well.... I know the 4x4 setup will take some time to figure out and build, so I figured I'd need to get cranking on it so I can get the Lil'Defender moving!
Someone suggested on the Toylander forum to look into using flexible/u-joints from socket wrenches. That's what I went with.
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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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  #11  
Old September 11th, 2013, 03:07 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
Posts: 1,642
Registry
August 2012 - Gearbox finally assembled

That's a lot of bolts, shafts, chains, sprockets and bearings to put together and line up correctly! In the process I have now learnt how to break and re-assemble chains with a hammer, nuts and nails!
You can see the vertical shafts that will bring power to the front axle.
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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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  #12  
Old September 11th, 2013, 03:12 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
Posts: 1,642
Registry
August 2012 - Reserve of power

I have no idea of the range of the Lil'Defender but I definitely want the kids to be able to enjoy it for a full day if possible. I elected to go all-out and get the biggest deep-cycle battery my local Costco is selling. Two of those babies is going to be heavy on the steering I am sure....
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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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  #13  
Old September 11th, 2013, 03:14 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
Location: Herndon, VA - USA
Posts: 1,642
Registry
March 2013 - front axle is in!

Where did fall, winter and early spring go???
Anyway... Front axle is now attached to the (partial) body. This is helping me out figure how much space I have everywhere, how much rubbing to expect, etc. This will also help me figure out where I can put the rear axles.
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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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  #14  
Old September 11th, 2013, 03:14 PM
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Chris
1986 110
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Cool project man. Many more pictures on the above link for those interested. Keep us posted!
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  #15  
Old September 11th, 2013, 03:14 PM
evilfij's Avatar
evilfij
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evilfij
I have never seen a rover in person
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It would have been cheaper and easier to buy the kids a disco I!

Impressive work.
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  #16  
Old September 11th, 2013, 03:16 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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March 2013 - rear axle is in!

Since the front axle went in, I put design the rear axle. Now installed, this is looking better! Kids have still not figured out what this is. Granted, when have not been in the garage much recently and it was up-side down until the rear axle was installed!
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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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  #17  
Old September 11th, 2013, 03:18 PM
MonLand
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Loic Fabro
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April 2013 - Will it move???

Well..... Put some temporary wiring in to get a feel of what I'm looking forward to have to do and.... It did not move! I pressed as hard as I could on the lawn mover clutches but they would not be able to transfer the power to the wheels while the Lil'Defender is on the ground. Since the wheels turns when off-the-ground, I know the gearbox needs modification! I had to take it all apart again!
Anyway, I "disabled" the clutch setup by drilling through the "clutch pressure pad and disk". It's a shame since I know I will need it when I will want to move the Lil'Defender without electric power....
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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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  #18  
Old September 11th, 2013, 03:19 PM
MonLand
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Loic Fabro
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April 2013 - Steering time

Now, it looks like I should have direct power to the wheels! So I need a way to steer the Lil'Defender around. I have not picked a steering wheel yet, so... I'll just weld something temporarily.
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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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  #19  
Old September 11th, 2013, 03:22 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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May 20123 - driveline setup: set back!

My driveway has a slope, it is the perfect setup to test the driveline.... Well.... That test failed miserably! I got to the bottom of the slope faster than I though I should have gone and when trying to reverse back up, I got additional noise and end up not moving anymore!

After further inspection, it looks like the lawnmower gearbox is not able to take the torque needed to move the Lil'Defender. I found two issues: one of the ring/pinion disintegrated going downhill and trying to come back up, the other popped out of its housing.... Was this a fluke? Not really, I'll skip that month or so of fiddling around, but after replacement, the new set will fail again with the same issues! We are now back to square one on the power transmission department.
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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! :) )
Reply With Quote
  #20  
Old September 11th, 2013, 03:23 PM
MonLand
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Loic Fabro
95 D90 - 96 Disco -06 LR3
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Join Date: Oct 2003
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May 2013 - more body progress

I've spent so much time on the drivetrain that I made virtually no progress on the body. Since it is now clear the Lil'Defender will not move for a while, it's time to focus back on what I can do.
And.... Unfortunately since I went outside for the test, the kids figured it out! Of course.... Having the build manual in sight next to it did not help neither.... Well, I needed them to help me figure a few space-related things!
Received the steering wheel, so I can roughly check how much clearance I have all around it (side panels and knees).
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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! :) )
Reply With Quote
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