TL-2 build in USA

[Helidoc67]

Trying to find 30mm screws in USA.  Will 1 1/8 inch screws work?
I think number 8's will be right diameter.  How many screws needed anyway.  Two boxes of 100 screws?
Progress has been slow. Snow helps as other jobs can't b done

[Richard]

Hi, you can use no.8 x 1.1/4" with the thread all the way up if you are careful not to countersink too deep. Once the body tub is complete make sure you go over the whole surface wherever there is a screw on the inside and flat the top surface well [where the point may push up a blemish in the timber]. If you do not do this you will get small lumps that show on the surface after you have applied the gloss coat.
Homedepot / Rockler
BW's
Richard

[paulr]

  Just had a quick measure 1 1/8th should be ok, just check that they dont come all the way through the wood if you go from the inside ie batten and then the outer wood otherwise you will have a few raised points. The alternative of going from the outside via a countersunk hole and then fillng it again if needed is a bit long winded. Two hundred screws should be plenty its best to be sturdy and have a few left than get to the last bit and find you run out. Glad to hear you are taking advantage of the snow to work on the Toylander.
Keep us informed.
PaulR and MrsR

[aosias]

Excited for another US Toylander!!  Any pictures?

[Helidoc67]

I am actually getting my shop ready to start cutting the wood;  Had tried to get a company to cut out the pieces for me, but the file was not readable by their CNC machine.

I had bought some tools prior to buying the toylander kit, and am actually still trying to learn how to use them.  have to admit, I am realising how big a project this is going to be, so am taking it one step at a time.

Bought my son a JOhn Deere tractor to keep him happy, as with my full time job and social activities, I have little time to devote to the toylander build.

Will post photos as soon as I have something to show though.

R U anywhere near Raleigh, NC?

Do you have pictures of your fully built TL?

Venk

[Helidoc67]

 :)Work is progressing slowly.  I have a question about Batten size and drilling.
I think I need 19 mm batten but when I fit it into a corner and and try to get my drill parallel to say the floor of the toylander, I am struggling.
Perhaps it does not matter if there is a slight angle.
I have fiddled a bit and used a piece of batten that is 21 mm square and my drill works fine.
Does anyone have any suggestions?  Can I make my own batten from plywood?
Getting my own batten square should not be too hard, just time consuming!  Has anyone else had to use slightly bigger batten?  What did you use?

Thanks
Venk
Drilling the batten before putting it in place will be easier Venk.

[paulr]

Hi Venk, yes you can use slightly larger battens just remember to adjust sizings of cutouts of other panels that fit over the battening.  The old bit of measure twice and cut once is needed here.
Happy Building.
PaulR and MrsR 

[Richard]

Work is progressing slowly.  I have a question about Batten size and drilling.

I think I need 19 mm batten but when I fit it into a corner and and try to get my drill parallel to say the floor of the toylander, I am struggling.

Perhaps it does not matter if there is a slight angle.

I have fiddled a bit and used a piece of batten that is 21 mm square and my drill works fine.

Does anyone have any suggestions?  Can I make my own batten from plywood?

Getting my own batten square should not be too hard, just time consuming!  Has anyone else had to use slightly bigger batten?  What did you use?

Thanks

Venk

NO you cannot use plywood Venk as in such small pieces it will disintegrate. BW's Richard

[Helidoc67]

Thank you, so predrill and counter sink batten.
Use awl to mark entry point on plywood.
Clamp batten to ply (if possible) and then screw in 30mm screw
Once dry fit done add glue and move to next section correct?

[Helidoc67]

Have not glued anything yet

but an test fitting panels

I am assuming that the inner wing total height of 273 mm is crucial on both sides so that the tops are square, I may have to adjust mine, to get the dead on.

here are some pictures of progress to date...

oops they are too big when taken with my iphone, I will have to reduce their file size and post later.

[Helidoc67]

Ok figured out how to export in iphoto and reduce file size.

Have not glued anything yet, just test fitting.

Think I will just stick with the 19 mm batten which I hope is available at Lowes.

Ended up using Baltic Birch 7 ply plywood.

Thanks Richard, and others for your replies, greatly appreciated// Venk

[Helidoc67]

 

Will apologise in advance, have some basic Qs:

In the floor panel, how big a drill bit is best for the axle holes 137 mm from the front?  and also for the handbrake mount and brake rtn spring?

The 60mm slots that are depicted in my diagram in the mid section of the floor panel 152 mm from the edge are meant to be how wide.   My diagram seems to lack this dimension, unless of course I am just missing it.

With the bulkhead, I have the same question how wide is the slot meant to be?

Looking at the door marking DIMMs, my manual directs me to P44, which in the June 2010 version talks about painting.

For those of you that used a router to make these marks in the side panels what size and type of bit did you use?

Lastly, I need some advice on how to clamp the batten to the plywood when dry fitting.  Do you only need to clamp the batten down to the plywood to avoid the batten lifting as the screw is driven in?  Are clamps essential, or just nice if you have them?

Since I have limited ( no experience ) with the use of wood glue, can i confirm that after the dry fit looks good, one removes the screws, then applies glue on each side of the plywood joint and between the batten and the plywood and then screws the batten to the plywood (? only one face of the plywood joint).  Clamping at this point is, or is not needed?

Sorry if these are silly questions.

Cheers,  Venk

[Helidoc67]

Figured out the handbrake mount and spring drill size, had not been looking at the full size patterns, so I think I can also figure out some of the slot sizes, but not in the floor panel.

Also can someone tell me what other modifications I need to make for left hand drive//vl

[Jason]

The clamps are not necessary, they are just another hand. Also not necessary after screws are in. I would recomend using a countersink bit. It is better to predrill or counter sink before appling glue.

[Helidoc67]

Thanks Jason, appreciate your advice