Making my own Land Rover from scratch

[Halfsize]

I'm going to build a Land Rover series one 107 from scratch, not a real one but a model that can be driven at around 70kph [biggrin]

I have gathered together a Kohlar 12hp motor and two three speed gearboxes plus the axles from a mobility scooter. Also got some 2x2 4 mm angle for the chassis.
The wheels are going to be 8 inch trailer rims pinched from a model trailer that I've scrapped

Wheels I'm using are going to denote the size of the 107 so starting from there, need to weld them to the little scooter rims so they fit the drive axle. I recon the Landy will be about seven foot six long

First problem I have is the drive train, I'm stuck with the 42 tooth sprocket on the diff because of the availability of larger ones to fit, might be able to bolt one to the one that is on there.

Engine is vertical shaft with pulley underneath, first gearbox I have is pulley underneath with 3 forward gears and reverse, out put is via a 9 tooth sprocket which is too small to weld or bolt a bigger one to it, also can't find a bigger splined one to fit
With a centrifugal clutch under the engine and the gearbox driving a 42 tooth diff on the eight inch rims (17 inch tall with tyres) I recon I'll get 10mph 0r less flat out on top which is no use,

I cant find any pulleys the right fitment to reduce the size of the plastic gearbox input pulley and can't change the small output sprocket on there so other things I can try are bolt bigger pulley under engine or try and sort a 60 tooth for rear diff

Another thing I can do is fit the second 3 speed gearbox in line to up the gearing, this will mean a two stick gear change, low, med and high plus three and reverse [biggrin]

So... small pulley on engine bigger (X2) on gear box input
Tiny sprocket on gearbox out put driving 42 tooth sprocket on diff
Not going to work is it

Only have a small budget so working with scrap, got an old classic Mini steering rack which I'll use long ways along the chassis operating the steering rods on the front axle, all I need now are brakes, looking like that'll be a disc brake and calliper on the back axle so not difficult.

Wish me luck, I'll be needing some body measurements though, only got length and width from landy drawings etc, they don't give such things as door size wing width, grill width and height etc etc

Budget is 1000 Aus dollars

[BradC]

Sounds like an interesting project. Look forward to seeing it as it evolves.

[goingbush]

Good Luck. $1000 is unrealistic.

Why don't you start with an actual mobility scooter and build a LandRover body on it , and still use it as a mobility scooter.

Disability vehicles kitted out to look like Land Rovers and Harley-Davidsons and are even appearing in new Robbie Williams video | Daily Mail Online (https://www.dailymail.co.uk/news/article-2336173/Disability-vehicles-kitted-look-like-Land-Rovers-Harley-Davidsons-appearing-new-Robbie-Williams-video.html)

[Halfsize]

Good Luck. $1000 is unrealistic.

Why don't you start with an actual mobility scooter and build a LandRover body on it , and still use it as a mobility scooter.

Disability vehicles kitted out to look like Land Rovers and Harley-Davidsons and are even appearing in new Robbie Williams video | Daily Mail Online (https://www.dailymail.co.uk/news/article-2336173/Disability-vehicles-kitted-look-like-Land-Rovers-Harley-Davidsons-appearing-new-Robbie-Williams-video.html)

Because
1 I can't afford to buy a mobility scooter
2 I have scrap bits I can use up
3 I want a petrol engine
4 I need to go more than 8 mph
5 Mobility scooter wheelbase too short for a 107

Also budget is a bit tight but I have bought most of the things I need and am under budget, just need the timber and paint [bigsmile1]

[Halfsize]

Spent so far on parts
converted to Aus dollars because I'm in UK

4 Reclaimed wheels reclaimed from trailer $ F.O.C.

Rear axle / front axle / gearbox.........$ 76.65

Two (half size) 12v Headlamps...........$ 20.47

12hp Kohlar 400cc petrol engine.... $287.43

Drive belt for above.............................£ F.O.C.

Mini steering rack.................................$ 47.91

Steel for new chassis............................ $ 86.23

Front leaf springs
salvaged from old trailer.....................£ F.O.C.

Centrifugal clutch ………………… $ 109.95


Total to date ……………………………. $ 628.64

Left to spend on timber and paint and any other bits $ 371.16

[Blknight.aus]

if you're looking to gear down, mountainbike front chain rings commonly(ish) come in upto 72 teeth and IVe seen some that are in the 85 bracket for racing bikes.

should be an easy bolt on

[Halfsize]

if you're looking to gear down, mountainbike front chain rings commonly(ish) come in upto 72 teeth and IVe seen some that are in the 85 bracket for racing bikes.

should be an easy bolt on

Yes good idea but I'm using motorcycle chain (spare from my bike) and also mountain bike stuff seems to be all aluminium and I'd feel safer with steel.

Been looking at go Kart stuff and found a 60 tooth one but have to check budget.

I've bought a small plastic pulley cheaply and hoping to bolt that to my large plastic gearbox pulley and see how much it gears up, waiting for delivery [bigsmile1]

[Slunnie]

Yes good idea but I'm using motorcycle chain (spare from my bike) and also mountain bike stuff seems to be all aluminium and I'd feel safer with steel.

Been looking at go Kart stuff and found a 60 tooth one but have to check budget.

I've bought a small plastic pulley cheaply and hoping to bolt that to my large plastic gearbox pulley and see how much it gears up, waiting for delivery [bigsmile1]

Kart chains are different to Motorbike chains, they're much finer. I was thinking a Kart motor with gearbox and/or centrifical clutch and sprockets would be a good way to do it, but I don't think that will happen within the budget

[Halfsize]

Kart chains are different to Motorbike chains, they're much finer. I was thinking a Kart motor with gearbox and/or centrifical clutch and sprockets would be a good way to do it, but I don't think that will happen within the budget

I can get 428 kart sprockets to fit my 428 bike chain but they are expensive
My rear sprocket on the diff is 42 teeth for 428 chain so ok there, hard to change that one as it slides over a cone shape and haven't found a sprocket with a large enough centre within budget yet.

Problem is that I have small pulley on engine and large on gear box, can't swap them over as they are completely different.
Then I have small output sprocket on gearbox (9 teeth) driving large sprocket on axle (42 teeth) can't swap them over either

If money was no object then I could buy the correct gearbox etc but I'm working with what I can get cheap and what ever I have in the shed

That's the challenge, get it all done and working for 1000 dollars, Held up with the weather at the moment [bigsmile1]188118

It'll look like the one in the picture except for the 5 stud wheels, mine will be 4 stud but look about the same

[Blknight.aus]

perfomance bikes have ally, kmart specials are still using steel, that said...

pretty much any motorbike/motorcross shop will have an assortment of sprockets in the scrap pile that should be good enough for what you want to do. Ive got 3 local to me that let me rat for nix when Ive got trophies to make.

they'll propbably also have chain and swing arm guides you can grab.

[Halfsize]

Could someone with a series 1 please give me the diameter of the wheels please ? (Height with tyre)

Thanks

[p38arover]

Do you want the nominal rim size (16”) or the overall diameter?

[Halfsize]

perfomance bikes have ally, kmart specials are still using steel, that said...

pretty much any motorbike/motorcross shop will have an assortment of sprockets in the scrap pile that should be good enough for what you want to do. Ive got 3 local to me that let me rat for nix when Ive got trophies to make.

they'll propbably also have chain and swing arm guides you can grab.

Good idea,
been to local Kart supplier and told to look on line[bigsad]

There is a bike dismantler not far from me so might have a ride over when it stops raining, best to turn up on a motorbike to a motorbike place I think, be a nice ride out as well

188119188120

[Halfsize]

Do you want the nominal rim size (16”) or the overall diameter?

Overall with tyre please
I have some wheels but they have big tyres on

[JDNSW]

Series 1 standard tyres are 6.00 x 16, giving a diameter of 28 inches or 70cm, and for the long wheelbase 7.00 x 16 giving a diameter of 30 inches or 75cm.

[Halfsize]

Series 1 standard tyres are 6.00 x 16, giving a diameter of 28 inches or 70cm, and for the long wheelbase 7.00 x 16 giving a diameter of 30 inches or 75cm.

OOOH Thank you !!!
My wheels are 15 and a half give or take so not far off half size [bigsmile]

They are maybe a little wide but I'll make sure they're inside the arches, happy days and thanks again [bigsmile1][bigsmile1]

188124

[Halfsize]

Stripped and greased axle and diff today[bigsmile1]
Unfortunately the diff will have to be on the wrong side due to the position of the gearbox output sprocket[bigsad]

Measure and bolted the axle to the chassis
Chassis too wide but need that to save messing with spacers on back axle, I'll narrow it at the other end so as it's correct when seen from the front

Next job is square it up and weld a couple of cross members in, hoping for some more dry weather


188138188139

[Halfsize]

Looking for a measurement again please

So as I can get on with my chassis I need the measurement from the forward edge of the bulkhead to the back of the cab
Can't get it from any drawings etc

Thanks in advance

[B.S.F.]

Looking for a measurement again please

So as I can get on with my chassis I need the measurement from the forward edge of the bulkhead to the back of the cab
Can't get it from any drawings etc

Thanks in advance
You have to use the doors as a guide.
.W.

[Halfsize]

You have to use the doors as a guide.
.W.

Thanks that's a great help. I can now cut my chassis and put a crossmember in to hold the bulkhead [smilebigeye]

I can just about get the door measurement from that as well but that's for later, must get the rolling chassis done first.

I'm a bit worried that 4mm rails at 7.5 foot long may not be up to it but we'll see, the DAF I made was 5mm, over 10 foot long, and didn't bend so fingers crossed [bighmmm]

Thanks again for doing that

[3toes]

While this is an interesting project have you checked UK rules/law around this type of vehicle and insurance requirements?

Not an expert but you need to be very careful where and when this is used once up and running

[Halfsize]

While this is an interesting project have you checked UK rules/law around this type of vehicle and insurance requirements?

Not an expert but you need to be very careful where and when this is used once up and running


Won't be used on the roads, it's too wide to use as a mobility scooter as well.
I'll be using it on a private road and on the fields, also driving it at shows alongside the little DAF truck [bigsmile1]

[Halfsize]

I'm looking round for a small alternator
Any one know if quads or ATV use such a thing ?
Wanting one second hand so I don't blow me budget
Seen a couple on line but out of my price range
Be nice to pick one up from a breakers if I know what to look for

Thanks [bigsmile1]

[Blknight.aus]

small as in amps or physical size.

small engines in bikes usually have one but its build into the crank area and isnt vehicle mount able

small kubota tractors have a 15 or 25 amp unit. as do the lighting plant trailers. smaller bobcats excavators

what did you need it to do?

2 on ebay

12V - 55A Bosch Alternator FITS Landcruiser J6 J7 J10 - 4 & 6 Cyl 2.4L - 4.0L | eBay (https://www.ebay.com.au/itm/254803655961?epid=2238968722&hash=item3b537b3d19:g:g-4AAOSwKcZf0ZX2&amdata=enc%3AAQAIAAAA4EyJD%2FOG3YFVw6bQoPq5Dx9Zr3% 2FKdftQIa6Oy01ObaDHLc4QPcpkyolrmHw%2FBxDYO1b%2F0Gu 6iKmeFtHlRflrKDsTmmAJ%2FFVGRpodaD0D3vv8lhacHp5ow7i dTT9fadzqu%2FW%2FFXCLz6A1Fej9REeHGcCKFESy0HxDQKs%2 BQzDYhkWg64bVtyYQOC2MV5yW%2BH9ViumoSXLfMCbUQMfDGNk h39fzL8A0zCknvxUoSPKxw7dww%2FBsV1yp6ahYeIC8if%2FD0 c4P4R9VOkxbyFwljRUR3X8NeU4Dj2lvNgnXMhxT2ji7%7Ctkp% 3ABk9SR-ChpayOYw)

Alternator For John Deere 415 425 445 X475 X485 X575 X585 X595 X700 1070 12V 20A | eBay (https://www.ebay.com.au/itm/114140912875?hash=item1a93541ceb:g:r~wAAOSwhXNipf~ 8&amdata=enc%3AAQAIAAAAwLyA4rGJRFWw0XQqddBglK%2FwGib M3Sw8rUlHSKUTifBPNHwKEchHGhDVh%2BsffX8C0A%2FbHrDuF pK41U0zTQ7Qg4Fto78jwZehjf00yIqwp7aYoHNTV9kHDVCAHPF 7SqxOyJJLP556kTIZUHWwxjRov9obrwA2haXW0IBgw7RonFose f%2FDFs34V9Os6hIyoXCAosoDV24aAM%2FRY9iett0h63fUlpC B%2F00Hh%2Fv9CWIOY3i7qv%2ByTQLepa%2FyXsQnHOCNmQ%3D %3D%7Ctkp%3ABk9SR-ChpayOYw)

[Halfsize]

small as in amps or physical size.

small engines in bikes usually have one but its build into the crank area and isnt vehicle mount able

small kubota tractors have a 15 or 25 amp unit. as do the lighting plant trailers. smaller bobcats excavators

what did you need it to do?

2 on ebay

12V - 55A Bosch Alternator FITS Landcruiser J6 J7 J10 - 4 & 6 Cyl 2.4L - 4.0L | eBay (https://www.ebay.com.au/itm/254803655961?epid=2238968722&hash=item3b537b3d19:g:g-4AAOSwKcZf0ZX2&amdata=enc%3AAQAIAAAA4EyJD%2FOG3YFVw6bQoPq5Dx9Zr3% 2FKdftQIa6Oy01ObaDHLc4QPcpkyolrmHw%2FBxDYO1b%2F0Gu 6iKmeFtHlRflrKDsTmmAJ%2FFVGRpodaD0D3vv8lhacHp5ow7i dTT9fadzqu%2FW%2FFXCLz6A1Fej9REeHGcCKFESy0HxDQKs%2 BQzDYhkWg64bVtyYQOC2MV5yW%2BH9ViumoSXLfMCbUQMfDGNk h39fzL8A0zCknvxUoSPKxw7dww%2FBsV1yp6ahYeIC8if%2FD0 c4P4R9VOkxbyFwljRUR3X8NeU4Dj2lvNgnXMhxT2ji7%7Ctkp% 3ABk9SR-ChpayOYw)

Alternator For John Deere 415 425 445 X475 X485 X575 X585 X595 X700 1070 12V 20A | eBay (https://www.ebay.com.au/itm/114140912875?hash=item1a93541ceb:g:r~wAAOSwhXNipf~ 8&amdata=enc%3AAQAIAAAAwLyA4rGJRFWw0XQqddBglK%2FwGib M3Sw8rUlHSKUTifBPNHwKEchHGhDVh%2BsffX8C0A%2FbHrDuF pK41U0zTQ7Qg4Fto78jwZehjf00yIqwp7aYoHNTV9kHDVCAHPF 7SqxOyJJLP556kTIZUHWwxjRov9obrwA2haXW0IBgw7RonFose f%2FDFs34V9Os6hIyoXCAosoDV24aAM%2FRY9iett0h63fUlpC B%2F00Hh%2Fv9CWIOY3i7qv%2ByTQLepa%2FyXsQnHOCNmQ%3D %3D%7Ctkp%3ABk9SR-ChpayOYw)

Both in Australia unfortunately (I'm in UK) and expensive

Need one to generate 12v power for lights, starter and horn and charge battery on my project, pulley driven off the crank and small if poss.

[POD]

I'd be looking at wrecked ride-on mowers. Any kubota dealers or repairers near you?

[AK83]

I'm looking round for a small alternator
Any one know if quads or ATV use such a thing ?
Wanting one second hand so I don't blow me budget
Seen a couple on line but out of my price range
Be nice to pick one up from a breakers if I know what to look for

Thanks [bigsmile1]

This is on Ebay (AUS), but I'm sure UK ebay would have similar stuff too.

Kubota style alternator (https://www.ebay.com.au/itm/114316657278?chn=ps&_ul=AU&norover=1&mkevt=1&mkrid=705-139619-5960-0&mkcid=2&mkscid=101&itemid=114316657278&targetid=1741701787658&device=c&mktype=pla&googleloc=9071257&poi=&campaignid=18278742238&mkgroupid=141565058112&rlsatarget=pla-1741701787658&abcId=9301725&merchantid=7364522&gclid=CjwKCAiA1fqrBhA1EiwAMU5m_zREcYA3fa7oQ-hQyTVMKNhuy5nrCA5XYadn80ZZ6RmgIBK0KQQXRBoCdcIQAvD_ BwE) ...

Dimensions are listed in the description.

[Halfsize]

This is on Ebay (AUS), but I'm sure UK ebay would have similar stuff too.

Kubota style alternator (https://www.ebay.com.au/itm/114316657278?chn=ps&_ul=AU&norover=1&mkevt=1&mkrid=705-139619-5960-0&mkcid=2&mkscid=101&itemid=114316657278&targetid=1741701787658&device=c&mktype=pla&googleloc=9071257&poi=&campaignid=18278742238&mkgroupid=141565058112&rlsatarget=pla-1741701787658&abcId=9301725&merchantid=7364522&gclid=CjwKCAiA1fqrBhA1EiwAMU5m_zREcYA3fa7oQ-hQyTVMKNhuy5nrCA5XYadn80ZZ6RmgIBK0KQQXRBoCdcIQAvD_ BwE) ...

Dimensions are listed in the description.
Nothing on uk ebay except vert very expensive new ones
There is a mower place local so I'll try there but it's in a well to do area so wont be cheap [bigsmile]

[Blknight.aus]

Just a thought, what engine are yout putting in?

[V8Ian]

I'm going to build a Land Rover series one 107 from scratch, not a real one but a model that can be driven at around 70kph

I have gathered together a [B]Kohlar 12hp motor and two three speed gearboxes plus the axles from a mobility scooter. Also got some 2x2 4 mm angle for the chassis.
The wheels are going to be 8 inch trailer rims pinched from a model trailer that I've scrapped

Wheels I'm using are going to denote the size of the 107 so starting from there, need to weld them to the little scooter rims so they fit the drive axle. I recon the Landy will be about seven foot six long

First problem I have is the drive train, I'm stuck with the 42 tooth sprocket on the diff because of the availability of larger ones to fit, might be able to bolt one to the one that is on there.

Engine is vertical shaft with pulley underneath, first gearbox I have is pulley underneath with 3 forward gears and reverse, out put is via a 9 tooth sprocket which is too small to weld or bolt a bigger one to it, also can't find a bigger splined one to fit
With a centrifugal clutch under the engine and the gearbox driving a 42 tooth diff on the eight inch rims (17 inch tall with tyres) I recon I'll get 10mph 0r less flat out on top which is no use,

I cant find any pulleys the right fitment to reduce the size of the plastic gearbox input pulley and can't change the small output sprocket on there so other things I can try are bolt bigger pulley under engine or try and sort a 60 tooth for rear diff

Another thing I can do is fit the second 3 speed gearbox in line to up the gearing, this will mean a two stick gear change, low, med and high plus three and reverse [biggrin]

So... small pulley on engine bigger (X2) on gear box input
Tiny sprocket on gearbox out put driving 42 tooth sprocket on diff
Not going to work is it

Only have a small budget so working with scrap, got an old classic Mini steering rack which I'll use long ways along the chassis operating the steering rods on the front axle, all I need now are brakes, looking like that'll be a disc brake and calliper on the back axle so not difficult.

Wish me luck, I'll be needing some body measurements though, only got length and width from landy drawings etc, they don't give such things as door size wing width, grill width and height etc etc

Budget is 1000 Aus dollars
Answer your question, Dave?

[Blknight.aus]

Answer your question, Dave?

not really, kholer 12hb yields a varieity of types some petrol some diesel.

some of the petrols have a swinging magnets in the flywheel type ignition...

If hes using one of the petrols that have that, it wouldnt take a clever man much to get say 3 or 4 trailer brake magnets put them inside the flywheel where the magnet goes past, wire em up to an alternator rectifyier pack and then a voltage regulator and... hey now you dont need an alternator you just made a dynamo (well technically its a generator cause the output would be rectified DC and its self exciting)

some have this already setup... check this vid.

Kohler 12hp engine teardown. - YouTube (https://youtu.be/Fp28xfhgyHw't=679)

[Halfsize]

Yes 12hp vertical shaft ride on mower engine with belt drive to gearbox then chain to back axle.

I have a BIG problem.

Working from plans for a 107 chassis I have marked out my chassis and the body measurements will not fit.

I estimate 7 " from bumper to front wing, 43"for wing, 2" for bulkhead, 33" for the door, 8" for rear cab panel and 40" from cab to rear axle. This leaves a very small rear overhang bit like an 88 so something is wrong somewhere and I can't work it out ! [bigsad] . ( 175.5 inch chassis length)

[Halfsize]

Used some different drawings for reference today and all body measurements now fit on the chassis so I can continue with the cutting and welding.[bigsmile1]

A break in the weather today so I cut and welded the front section of the chassis ready for the leaf springs, but of guesswork involved but I'm sure it'll be fine [bigsmile]
188217

[Halfsize]

Job stopped for a while now, it's been bitter cold out
Chassis jigged up for welding though and I've worked out how to fit axles and wheels
Roll on some warmer weather [bigsmile1]188564

[Halfsize]

Well, been helping my mate with his series 2 88 with Harvey Frost crane, nice Landy

Last week I decided on the little landy front suspension, working with What I have I'm using a mower front axle mounted on the leaf springs. Shortened leaf springs will act as trailing arms with small coil over shocks to support the weight, panhard rod should keep it in line

Front wheels are steel with the old plastic mower wheels as a hub.


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