Sunday 8 March 2009

Building your Toylander kit




Our Toylander number one,note the inovative 'finger joints' that hold the plys together,which greatly simplifies your assembley,this is a design idea taken from our ocean racer boat kits that we developed to help assembly times.




The stylish Toylander logo

This list is assuming you cut your panels from your own plywood sheets,in the case of our kits which are fully CNC cut,supplied with finger joints which hold the shell together,some of these tools will not be required,we can also supply a fully finished shell,either in primer or fully painted to the colour of your choice.We will be building and completing a new demonstration Toylander very soon,we will start wiith the Toylander 2 option,the car will be fully built and all componants will soon be available.

A message from Lorna:

Wow, incredible!!
Your little Grandson would be over the moon!
Like the tractor ones too!
Xxx

Lorna


TOYLANDERS are a straight forward build and can be assembled in around 50/60 hours prior to painting and detailing. Children from 3 through Adult [85 at last count] enjoy the features of a real car in miniature including forward, reverse, foot and hand brake, lights, horn; folding screen and opening tailgate. Both are identical in weight, size and performance, the difference is cosmetic; S1 manual in metric sizes; S2 manual shown in inches.



Motive Power: Power is provided by one or two powerful 12 volt 180 watt air-cooled, continuous rated, reversible, permanent magnet DC motors, driving through a 25:1 ratio gearbox. The cars will run on one motor and a 12v battery at a speed of around 4 mph depending on the size of the load and the terrain. Final drive is by chain to one rear wheel if one motor is fitted or both wheels for two motors. Forward or reverse is selected via a switch.



Transmission Options:

Basic is Direct Drive, 12v straight to the motor, used on most demonstrators.
Soft start control ramps speed up to full over three second period; for very young children.
Speed control operates through a linear potentiometer for a real throttle response from crawl to top speed.
Buy an extra battery and motor, wire in series, drive both rear wheels and get a 'diff effect. This level of control allows you to teach proper reversing of a small trailer. Also ideal for gentle paddock use. (All turn key toys are supplied with two motors and electronic speed control)
Remote control by hard wire. Forward / Reverse and speed control from box in hand; sat in passenger seat or walking behind.
Front Suspension: Complimentary to the basic set up: a swing axle or sliding pillar suspension. The former helps the driving wheels to maintain ground contact, the latter takes shock out of the steering wheel and softens ride.



Increased Speed: Speed control set up, 24 volts and two motors achieve a top speed, even with an adult on board, near the soon to be legal maximum. 6kph being the speed allowed in a public place i.e. pavement, car show or steam gala and the local park. Public liability insurance is required by most show organisers and a good idea too.



Body Construction: The immensely strong body is of monocoque construction; cut from 12mm (1/2") thick panels in light weight, CNC cut Ockume veneer marine plywood. No chassis required, axles and other fabricated parts simply bolt directly under the wooden floor.With our special finger joints and epoxy fillets,followed by a thin epoxy coating inside and out,you have a super strong and water proof bodyshell.



Fabricated Parts: The steel parts can be either made in your workshop from the simple working drawings shown in the Build Manual supplied. For those who need the quicker build all parts are available from our full stock list.



Assembly instructions: The assembly instructions are easy to follow; each stage is explained in plain English and illustrated with simple drawings. Workshop support available should it be required.



Wheels: The wheels supplied are road quality pneumatic tyres on 3.50 x 8 inch dia. steel rims running on 1" (25mm) roller bearings. Total tyre diameter is approx. 15 1/2" (395mm) for S2 and 16" [401mm] for S1. The drive wheel is supplied with an extended hub, an extra bearing and fitted with a drive sprocket. Wheel rims have smooth rolled return edge to comply with toy safety and use the flat of the rim for the braking surface. Knobbly tyres available.



Battery: A 12v, car battery is normally sufficient but if buying new or using electronic controls, a sealed 'deep-cycle' semi-traction battery (golf trolley style) would be preferable for ultimate performance. We currently use a 35 or 33 amp hour fully sealed mobility battery. The alternative is an 85amp/Hour leisure battery [only use one with a looped overflow pipe to catch acid]. Make sure your charger is suitable for these batteries.



Curved Sections: The extreme forward ends of the front wings are formed from small curved aluminium sections. The bonnet is also formed from another piece of aluminium. These can both be supplied ready rolled if required.



Duration: Continuous play value in stationary form, up to four hours driving time, all day in flat garden. This varies according to load carried, terrain encountered and battery size measured in ampere-hours. Twin motor set up 7 hrs



Measurements: (approximate; depending on careful cutting) Height (with windscreen folded): 30" ( 762 mm ) Length: 67" ( 1702 mm ) Width: 29"( 737 mm ).
Weight: Basic kit inc. packaging: 38kg. [ 83lbs ] Ready Cut panel set: 41kgs [ 90lbs ]
Basic car, without battery: 75 kg. [ 165lbs ] Twin motor model, without battery: 85 kg. [ 187lbs ]
New mobility battery 11kg. Can be posted. Single 85aH battery: 19 kg. [ Can not be posted ].



Tools:
Jig saw with adjustable foot to cut angles, fine tooth blades and some narrow blades
Electric drill plus assortment of drill bits and hole saws or 'Forstner' bits and countersink
Protractor for setting angles, school compass
Pop rivet gun with variable rivet sizes
Hand saw, Hacksaw, Knife
Assorted screw drivers
Tape measure
Hammer, mallet, roll of tape
Rasp, files, surform or similar and selection of sandpaper
Assorted spanners, Allen key, pliers, scissors, snips etc..
Bench mounted vice


Small Land Rover models for children and adults to drive made of wood and electric power. Plans, Parts, Kits, Ready cut panels, Ready made bodies.
Copyright:
Jeep © is the copyright of Chrysler LLC and Chrysler UK Ltd.
Land Rover © and Defender © are the copyright of the Ford Motor Company

Please note: we will only supply you with a CNC cut kit set on proof of your purchase of plans from Real Life Toys Ltd.

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