Reinforcement Advance...

[pdw709]

A few years ago I converted my kids Toylander from a 12V single drive to a 24V dual battery/motor set up, basically to allow the kids to tackle rougher ground. After some hard use I noticed that the extra weight of having two batteries under the bonnet had caused the floor of the bonnet/battery area to start coming away from the sides of the tub. i.e. bending downwards. You could clearly see the front bumber (attached to the under side of the floor) moving/flexing up and down when under hard use. Upon closer inspection the glue that had been holding the battens in place had failed along with the front screws.

It was an easy fix using extra screws/glue and some flat L plate brackets on top of the batterns right at the front.

[Richard]

Hi PDW709,
This is a new one on me after twenty three years so a photo or two please if you wouldn't mind? Also what material is the body made of, what sort or brand of glue and finally on the material front what size batten and screws please. I am assuming two car or caravan batteries so what mounting system has been employed please? The answers will allow me to assess what level of reinforcement or recommendation we need make. The test vehicle we use has not shown this situation up to now having been used in earnest and on some full size trial sections put on by the Anglia Rover Owners group.

Richard
UPDATE OCT 2010: The glue let go. It is important to make sure the area to be glued is clean and plenty of glue is used.

[Tombraider]

Maybe if the batteries were not strapped down, I could envisage that on rutted ground, they could bounce up and down a lot causing a shock load on the floor which could put a lot of strain on the glued joints. (I haven't strapped my own batteries down but I have made a dummy engine cover so they can't move as much).
If you are going to use it in a rough field continually, have you thought about putting suspension on it? There are some really great vehicles on here that have used quad bike spring/damper units.
I expect most of these only get used on tarmac pavements or in local parks/gardens with smooth lawns or fields.
Regards
Mike

[pdw709]

Tombraider, thats a valid point, and a mod that I will try and do when I get a chance. The suspension option is also a possibility, but thats more of a long term mod/winter project if I get time. Now that I've strengthened the joints I would be surprised if this is an ongoing problem on my car.

Thanks for the advice.

[pdw709]

Okay, sorry this took a while.

Hopefully you can see my picture below, showing the reinforcements I've incorporated to repair the floor of my car.

The additional screws are actually on both sides of the bulkhead, but you can't see the ones on the other side as they are hidden by the battery and the horn.

Just a reminder that the front of the floor was bending down and separating from the battens which had been fixed during the original build using the screws/glue as per the instructions. I also placed a battens on the floor tightly around the batteries to stop them moving around, but this would not have prevented them from jumping/moving upwards. I have since modded (not shown) by strapping the batteries down to ensure that they don't move.
Hope this helps.
Phil

I'd really appreciate a few detailed photos to the works address please Phil and what material did you use please? Many thanks Richard Update Oct 2010 Thanks for letting us know it was a gluing problem.

[multisync]

Hi Guys
Thats all a bit interesting, I've been following this thread and now it's resolved I thought I'd add my comments.
I have batteries that look just like in Phils photo, but mounted side by side at the rear on the engine compartment. They sit on battens glued to the floor so it's possible to pass cables under the batteries. This way, the weight is a bit further back on the floor pan, and there is then room at the front for the lighter components, such as a charger or control gear, which would then be directly behind the grill for cooling purposes. There is a batten across the compartment in front of the batteries to stop them moving forward. I also have a strap to hold them down but I don't normally fit it, perhaps I should.
Best Wishes
Walter

[Richard]

Yes Walter, it's a strange one.
I'd estimate at well over a thousand Toylanders supplied since their inception in 2000 and that's not including the guy's who make everything themselves. Then there are the Geepstars, goodness knows how many of those since 1988 and this is the first time anyone has identified this issue to date. I think it is the kind of thing someone would have mentioned had it happened to them just as Phil did. I even spoke to JC who started the business in 1987 and he has no recollection either.

I have asked Phil to send me some photo's and when he has time, to answer the questions on timber used, glue make etc. I'll know more then.

My grandson took a Geepstar I bought locally to bits recently; we wanted to put in the latest body panels in the rebuild. Luckily for us this fellow had assembled the body straight on top of the patterns so the joints came apart relatively easily when the paper split. It's a trick we use on purpose when making the tractor bonnet. We glue the bonnet top holding batten on some sacrificial paper and then glue that to the side of the battery box and when we want to remove the batten, it comes off quite readily with a little banging.

I want to get to the bottom of this situation.
Best wishes
Richard

[multisync]

Hi Guys
I don't think anyone should get unduly worried about this. Whatever the cause I think it's a one off, especially as the axle beam is right below the battery compartment and will take any amount of weight. I've used the same construction method on other projects and if made correctly this type of construction is immensely strong and extremely difficult to break. The joint should end up stronger than the original timber.
Take Care
Walter

[markh15]

Hi Guys,

Maybe it was the adhesive use, but it's not a problem I've encountered in the two plus years that Harvey's Toylander has been built.
 
It's not that he's that gentle with it either, and has crashed it into some very solid objects and given it some very rough use in this time, it's a strange one that's for sure.

Keep On Toylander-in',
Regards,
Mark.