Volkswagen Support Truck Build Thread

[Wrc action]

Right moved from the monster truck thread to here as I feel it will be of more interest with the other build threads on this part of the forum.

Basically its a project to covert a CC-01 toerag chassis into a dakar support truck in order to support my new TB02 based touareg that can be found on the following forum link

TB02 based Touareg

The basic idea was a bruder cab and a custom rear box section to make a machine that is capable of transporting some spares and batteries around the beach or on walks, as well as recovering my car should it need to be :L

now to the build

I had a look around TC and taking a few ideas Dad and I have came up with the following concept to mount the cab on a pivot at the front allowing it to tilt forward in a realistic manner giving access to the front gearbox.

Also built into this is our plan to revise the front steering system. Our plan is to bring the steering arms in the front of the chassis on a simple set up to a servo mounted on the plate. As thus we have replaced the front hubs and C-hubs with GPM aluminium ones which has also widened the front track that should aid stabilty. The plate for mounting the cab will also act as a mounting plate for this servo upside down.

The plate has been worked upon so far in 0.5mm mild steel which is ideal for this prototype stage being easily malleable and ductile. The final version of the plate will be made from a far tougher metal thourgh dads work.

In mounting this the bottom chassis part of the bruder truck needs holes built in for a bar to be added. This has proved difficult to get a dead straight set of holes. However so far things are looking positive tho new holes do need to be drilled to lower the front end down to a more scale level as in intial mounting was to high.

And finally a health and safety warning

TAKE CARE WHEN DRILLING A BRUDER SHELL

and if in doubt - get a dad to do it :L

best regards Ryck

[Wrc action]

Well today Dad and I managed to mount to the cab and work with the hinge set up - There has been a lot of trimming needed to get the cab to sit properly and this has thrown up some new problems for mounting the servo as the plate is too low for our servo ends and the servo doesnt fit upright in a TL-01 style set up. As you can see here with the cab titled up the room for the servo is actually way less that anticipated.

As thus does anyone know where I can get decent minature servos with the power of an AS-16 or more? and preferibly waterproof to fit into the smaller gap, and also maybe a disc like servo attachment that will be better than using an arm like setup.

Finally mounted the entire bruder cab onto the truck -

this still needs to be secured at the back - does anyone know where i can get suitable catches/locks maybe to secure the rear end of the cab down and also bring it fully into line as the front end has some slop with the holes larger than the rod to take into account inaccuraces in the hole drilling as it was very awkward.

I have decided to keep the cab yellow as VW where sponsored by shell and I believe still are to a degree so it will get a few shell decals, Reasons for this is that I dont want to make a haulics of it and ABS isnt my favorite painting surface

Just some decals should be easy, I have got some massive redbull ones which are for bikes of ebay so they should look awesome.

In fact I will go and do that now, Enjoy the pics.

Regards Ryck

[Wrc action]

Now to the genuinely new developments.

I have started work on the box section for the rear of the truck, Sizes 26cm long, 18 cm wide and 15 cm tall.

It is to be made out of aluminum box section and secured together using 3mm nut and bolts.

Firstly I cut all the box section out to the required length, that being 4 of each size as seen below.

Next I test fitted the base to ensure that all the lengths where correct and it they fitted together well.

The Test fitting was then continued with bluetack used to keep the parts in place.

Finally I placed the box section on the back of the truck using a few simple blocks just to see how it looked and wat heights I would want to use for the mounts

The next stage is to screw the box together with 3mm screws, does anyone have any suppliers or ones they would be willing to part with?

And also to procure some 1mm/2mm polycarbonate sheeting to do the sides of the rear section, again does anyone have any ideas about suppliers?

espically those that could cut to my sizes as that would ensure the best possible finish.

Cheers for reading

Ryck

[Badboy]

Try:

http://www.modelfixings.co.uk/fixings.htm

Good luck!

Looks great so far!!!

Badboy

[Mud-Plugger]

For fasteners I use teknikr6 on ebay, he has always delivered next day. servicechampions I have also used but delivery times unacceptable.

Mud.

[kingeddie]

screwfix direct do 3mm in mild and stainless in various lengths, and nylocs to suit, used them extensivly on my support truck body, very cheep too!

[Wrc action]

Cheers Guys, I think will use that supplier badboy for my screws as thats how I am going to put the rear box section together,

Mud-Plugger, Yes I will check them out for the fixings, I need ones for the back of the cab and the access doors for the rear and side of the box section.

Kingeddie - Cheers my B&Q metal was 10 so cheaper is gr8 for future reference and we have used screwfix before as dads account should prove handy now

yes your bowler truck is superb, really hope mine comes out as good, How did you get it 4wd?

I have sent two drawings for the mounts for the rear box section down with dad to work this week so hopefully I shall get them back this weekend

[jacolouw]

Hi

Did you had a look at my VW Merc truck yet - Started as a std Merc 1:14 chassis. Have a look here.

VW Merc Dakar Truck

Jakes

[Butler]

Wow both really cool projects. I love the dakar. I watch it everynight on Eurosport when its on.

[Wrc action]

Thanks for your kind comments Butler - I also love the dakar and just wish tht i could get more coverage of thr rally raid world cup in the mean time, to i heard some where that the paris pe-king raid was going to restart sometime around now. Any ideas?

Jakes - Yes I have seen your truck, gr8 work there. have you run it on any sand yet? I have managed to track down some really nice and big bike redbull decals to put down the side of the rear box section. That I will hopefully screw together this weekend. the mounts are being made down at dads work and should be gd by the end of next week - 1mm stainless

[Wrc action]

Time for an update as the brackets arrvied yesterday - Many thanks for Gareth from dads work they are superb,

The arrival of the brackets after returning from work has supered me on to work more on the truck.

I have provisionally secured the cab with velcro and tie wraps, a more permanent leaver method allowing the cab to tilt forward will be added at a later date most likely mounting upon the rear box section as there are precious few mounting points within the CC-01 tub chassis.

I have decided to return to the normal CC-01 steering system tho the aluminum front hubs and C-hubs have remained as they give a wider track than the stock setup with it gd for stability. I have cleaned it all out and it works pretty gd with an AS-16 servo tho I am planning to replace the plastic shaft with a metal rod and bearing as per the how to guide her on tc that is done either by chain driven or mud plugger - cannot remember which one of you two wrote it, sorry

The electrics have also been added low in the chassis with the reciever right at the back and the esc just infront of it - all down below the line of the rear box section and out of the way. The electrics will slow be upgraded and waterproofed to be able to withstand some serious fording

Next I made a trip to focus, gr8 being able to drive legally now 4 packs of long m3 screws with nuts - 40 in total for 4 i dont think is to bad tho they will need to be trimmed down for the rear box section, Tho before constructing the box section I needed to test fit the rear bracket. This fitted near perfect a little bit wide on the holes tho nothing that a little plastic flex cannot absorb, The plate will screw direcly onto the steel base of the rear box section, heavy and secure is the design here as it will be carrying all the spares and batteries for my race touareg.

The front bracket which goes where the radio gear should be mounted according to the instructions has also been fitted and went on superb with regards to the holes pre-drilled in the base of this part - Thankyou tamiya they are all spaced to values of 10 mm which made designing the parts so much easier :L This second bracket deliberately sits some 4mm shallow of the other bracket, a distance that i left to allow me to make it up using the rubbers from servo mounts and other items just to get more control over the rear box section height and also by using rubbers hopefully a little bump suspression :L

still its to dark for decent pictures of this section now so I will leave it for tomorrow and instead put in two pictures of the front of the cab.

as ever comments are welcome as are any pointers - Some highlift tyres are coming soon and I would ideally like to double them up on the rear for a bigger print, any ideas?

cheers Ryck

[Wrc action]

Firstly a picture of the front bracket installed into the chassis - this will hold the front of the box section up using 2 4mm spacers to go in between the bracket and the base plate of the box section.

Done som more work now over this week as the rear box section is now all completed.

Started off simply by lining up each part and then drilling using a wooden block as a jig, the parts where screwed together as the holes where drilled and corners filled down to give a flush finish.

The base plate for the box section was also screwed into place and will be used to mount the box section to the front and rear mounting brackets. the corners of the base plate also had to be trimmed to avoid the screws. Each corner is screwed with 3 screws for maximum stabilty and strength, I chose to use screws over rivots as it would allow disassembly of the box section for painting later on as well as replacement of any parts should they get damaged :L

[Wrc action]

Continuing just taken some more pictures to show the completed box section.

mounting the floor of the rear box section

the problem with 40mhz recievers the aerial is extremely long, so has to be wrapped around the inside of the rear box section - I am still yet to test and see what this has done to the quality of the control, I think i will effectively enlarge the aerial, any opinions out there?

You can just see in the bottom picture the blue foam that I have added to level off all the screws that poke into the rear box section, Once all completed I hope to make a full interior to safely hold batteries and other spares for the run

[Badboy]

I really like pic #2!!!

Nice garden!

I like the colours...

Naaaa, kiddin' with ya'!!!

Looking good so far!

Badboy

[Wrc action]

I really like pic #2!!!

Nice garden!

I like the colours...

Naaaa, kiddin' with ya'!!!

Looking good so far!

Badboy

lol cheers mum will be so pleased its a little tight for rally racing but gd for shakedown espically in the winter when it can get a little muddy

Cheers there is still much work to be done tho sure it will look gd wence completed. It ran at wrexham last week with dad landy as well, once I had changed the silver can for one that hadnt got a nut stuck in it :L also brought a lathe motor from Rich (biggusditchus) so should be fitted soon. Also a video from him shows it so far.

cheers Ryck

[Wrc action]

Ok update added a lathe motor from rich - really has slowed the thing down and the motor seems to be hardly working under normal driving.

Think a 20 turn pinion is in order - anyone got one spare?

Also ordered some 2mm black plasticard for the sides will be painted on the outside with tamiya TS metalic blue and held in with double sided tape or velcro so that should it role on to a rock/mound the sides will just fall inwards and not end up with a huge hole in them.

Update pictures soon.

in the meantime found this really good dakar highlight video from this years 2007 dakar.

http://youtube.com/watch?v=9GN8ipxN4bI

cheers Ryck

[Wrc action]

update my plasticard has arrived. And using some brackets I have installed some of the panels as well as cutting all the rest.

Same procedure with the screws as before.

using square brackets to attach the side panels.

side done pending painting with some auto paint I brought today.

cheers Ryck

[Badboy]

Ahhhh....

Updates!!!

Sweet! Looking awesome!

Badboy

[Wrc action]

Cheers for your comments Badboy - are you a dakar fan likemyself?

Its coming along nicely at the moment. some more news is that I am going to need to re-locate the battery as with the sideboards it'll be blocked in :L

as Thus its going to go into a craddle right out the back of the box section. mounted laterally accross the section with the cells like this

O

O

It will be slotted in from the sides and add some much needed weight to the far end to counteract the cab at the front. I will also be widening the rear track with wide tamiya blocks or even some wheel wideners like on my race touareg.

to get around 5mm more on each side and bring the wheels out of the way of the battery entirely. ALso going to revise the fourlink with proper links like my fathers defender as the plastic ones bend to much for my liking.

cheers Ryck

[ryanbored]

I love this tread; anything that isn't always a straight forward box build is good, even if i'm not particularly interested in the intended outcome.

Keep it up, i know you can sometimes lose focus towards the end!

Ryan

[Wrc action]

I love this tread; anything that isn't always a straight forward box build is good, even if i'm not particularly interested in the intended outcome.

Keep it up, i know you can sometimes lose focus towards the end!

Ryan

Cheers for your comments and I have to agree. I love to see what other people are building and wish that the forum was full of these kinda threads for all sorts of cars rally, f1, dakar, trails etc ]

cheers Ryck

[Petrolhead]

You're doing absolutely great work Ryck, I love to see these build threads and am sure everyone else does too. The truck's coming along great, can't wait to see more progress. Keep it up!

[Wrc action]

Cheers Allie - This has reminded me to go and take some new pictures when I get home tonight, So keep an eye out for the updates.

Cheers Ryck

[Wrc action]

Well finally got home when there was just enough light to take some pictures of the present machine. The rear box section is now completed and the side's are also mounted using brackets as shown above, the Ends screw into the cab with a nut and bolt ensuring that it remains in the right place whilst the truck is running.

I have relocated the battery out the back of the truck into a craddle that will be covered in more plasticard in time. The rear doors where also added and a simple securing mechanism that will be mirrored both top and bottom in time. A pair of spare wheels will also be added to the rear end in order to increase the overhang as it looks a little - sawn off at the mo :L

Motor is a 55turn lathe motor from Rich (BiggusDitchus) along with the 20 tooth pinion which gives it a decent top speed and still loads of torque enought to make the think wheely a little from a standing start and a full wheels if u go frm full reverse to forward. I think I will be fitting a 5th damper does anyone have any pics on how best to fit this?

best regards Ryck

[BiggusDitchus]

Its looking great but I think your wheely problems stem from where the battery is located.. think of where the battery is fitted on a Wild Willy to get it to wheely. If you mount the battery in the front of the box low down it should be much better balanced. The fifth shock would fit on left hand side of rear 4 link to stop it twisting. (either that or you could just put heavier shock oil on the left side with some preload spacers on spring)