The making of a Dutch Toylander II

[markh15]

Hi Robert,

The selling of the motorbike sounds like a good reason to get it finished!

As for the future modifications and tweeks, that's what winter is for, so that Dads, Grandads, etc can modify the little cars, summer is for 'Toylandering' and motor-biking, so I'd get busy!!

Good luck,
Regards,
Mark.

[Robert]

Started designing the forward / backwards lever this week.
Firstly I needed a suitable switch and found an Omron limit switch in my stock of used parts.
It is provided with 1 NO and 1 NC contact, but I need a change-over contact, and solved this by connecting the +24V to 1 side of both contacts.
Tested it and this works perfectly.

The lever wil be retained in both positions by means of two springs that detent it.
I will start building this next week and hope it works as expected.

[Robert]

forward / backwards lever:

started building the lever last week:


Luckily I found all the required parts at my "used parts attic"
My wife never understood why I brought home all these parts since I started working as an engineer, but now she does! 











The lever works perfectly, looks good (at least in my opinion) and gives the kids good control over the TL.
The system with springs gives an opportunity to set the force for "shifting the gear".
I will probably add a neutral position to it because the controller needs a signal that shuts it off while other electric functions keep working.
The idea is that the controller wil be shut of by means of a micro switch while the lever is put in the neutral position.

[Robert]

Hi Robert,
Once you get the bugs ironed out of the system, it will be fine.

You say you've moved the batteries under the seat, how has this effected the space in the rear of the body?

Some pictures of this modification would be really nice to see.

Sounds like the kids are eager to take delivery.

Looking good, keep up the fine work,
Regards,
Mark.

battery compartment:

Mark,

the batterys fit nicely in the standard compartment under the seat. I just had to re-arange some of the 20x20mm wood parts.
Please don't mind the wiring, they are still under construction...  

[markh15]

Hi Robert,
Thank you for the picture and explaination.

I see now how you've managed it. It's a pity that you have had to use 3 batteries, otherwise they would have fitted neatly under the seat and given you more legroom for the kids in the rear compartment.

I like your gear selector too, very neat and well engineered, a credit to you.

Keep Busy,
Regards,
Mark.

[Robert]

Lock for the bonnet:

I used a lock from an old electrical cabinet and slightly modificated it by adding a bend to it.
The bend fits in a angled piece which I fastened to the bonnet, this works fine, another job finished!

[Robert]

Hi there,

here are some short video's of a try-out with the Toylander:


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[paulr]

  Looks like the test drive went very well including the test drive of a small turning circle and the hill climb.  Was that wall really as close as it looked Well done with the build so far keep it up.
PaulR and Mrs PaulR 

[markh15]

Hi Robert,

Congratulations on the test drive!  The little car goes very well, and has no problem with the incline. It looks as if the 36v system has it's merits over the 24v one.

The only problem I can fore see is the children, you are now going to be pestered to death with the 'When will it be finished Daddy?' question!!

Well Done,
Keep Busy,
Best Regards,
Mark.

[Robert]

The only problem I can fore see is the children, you are now going to be pestered to death with the 'When will it be finished Daddy?' question!!

Hi Mark,

you got that right!
But I'm used to it since the previous pocketbike project and suffer now from some sort of selective deafness. 

[Robert]

More electrical work:

I have upgraded the gear lever with a neutral position and a micro switch.
This switch shuts of the controller while the gear lever is in neutral, because I was afraid that sooner or later an accident would happen while the kids were stepping into the Toylander and touch the throttle pedal.
Now I must teach them to use this position properly. 





At this moment I'm trying to understand the wiring and make an electric diagram of it.
I'm encoding all the parts and main wires. This takes a lot more time for me to do then the guy needed who connected it all. 

[markh15]

Hi Robert,

Spaghetti Anyone???

Two large jars of 'Dolmio' should cover it, I think!!

Regards,
Mark.

[Robert]

Mark,

are you challenging me?? 
You just wait and see!
I have disconnected everything to make it look neat, but if I get lost in the wiring, I 'll need you to come over to the Netherlands and save me ! 

[markh15]

Hi Robert,

I hope the 'Toylanders' not under that lot!!

You'd have to be pretty desparate to want wiring help from me.
I blew out the indicator circuit on Harvey's car looking for a feed wire for the horn!!

It took me three weeks to trace the fault, I had to practically dismantle the complete loom to find it, and it ended up being a small circuit board hidden away (by me while building), that was the problem!

But if you're offering a free trip....

Keep Busy,
Regards,
Mark.

[Robert]

Speedometer:

A car is not complete without a speedometer, so the TL needs one also.
The easyest way to get an indication of the speed is to measure the voltage at the motor.
It was quite difficult to find a 36 volt meter, but eventually I found one on Ebay in the USA.



I had to open the housing to change the volt scale for a speed scale. Since the plastic housing was glued I had to cut it open on the lathe.





Theoretically, the Toylander can reach a top speed of 7,4 km/h.



The Land Rover sign is there to cover the cut for placing the scale around the axle of the meter.



The metal shell connects both parts and is also used for clamping the meter at the dashboard.