Making my own Land Rover from scratch

**Halfsize** · 11th December 2023, 08:07 PM

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 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

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** · 11th December 2023, 08:57 PM

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

**goingbush** · 11th December 2023, 09:27 PM

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

**Halfsize** · 11th December 2023, 09:37 PM

Originally Posted by 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

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

**Halfsize** · 11th December 2023, 10:18 PM

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** · 12th December 2023, 08:28 AM

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** · 12th December 2023, 07:21 PM

Originally Posted by 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

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

**Slunnie** · 12th December 2023, 07:50 PM

Originally Posted by Halfsize

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

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** · 12th December 2023, 08:29 PM

Originally Posted by Slunnie

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

1-1.jpg

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** · 12th December 2023, 09:47 PM

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.

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