Project in progress: 

This is my goal for my 3 year old son.


This is where I am to date, 6 months into the project:
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Have used my MFT/3, TS55, Qwas dogs, OF1400, MFS 400, T-15,  ETS 125 EQ, PS 300, my parallel guides and my Festool beltsander (run off my generator, which I do wheel outside!!)

I had to make a jig for the beltsander until I can get the stopper from UK


I will be using my domino with a home made jig for 1/2 inch material.

I have found my benchcookies from Rockler really useful too.; of course modified and Festooled with lime green duct tape!!

Even though many of my tools were bought to build this project, even I could not justify the cost of picking up the VAC SYS on my last trip to UK, so I modified the vac-clamp a carvers clamp and a foot switch to make my own affordable version.

It works for me and has been very useful so far... [ ERROR: SPECIFIED ATTACHMENT MISSING ] ]

So useful that if they ever bring the vac sys to USA, i would buy it for future projects, just so i do not have to run my air compressor.

Considering what I do for a living this woodworking project so far has been a great stress reliever.  Have had as much fun learning the tools and coming up with jigs/ modifications as I have building the toylander.

Hopefully my son will not have finished highschool by the time his Toylander is completed.

Venk

For more info on toylanders here is the link to their website.

http://www.toylanderownersclub.com/

Thanks for the interest: I have taken an age (6 months)  to get this reply put together and Nigel’s comments made me realize that some might be curious.

Progress was slow initially the first 6 months were hard, so far about 12 months into the project.

After getting plans from Real Life toys and the the majority of the metal parts, motors and wheels, I eventually decided upon cabinet grade plywood.

I have to admit that I am having to relearn some skills from comprehensive school in UK. 

Anyway, have been helped a lot be reading the forum, reviewing videos and essentially learning along the way.

I cut out the floor base twice, as the first time I was off by a few mms, to be honest I did not really understand how to mark the wood properly and where on the line to cut.  Anyway second time, I used a combination of the TS 55 and guide rails and my PS300 also on guide rail.

I did not use the paper plans supplied, I thought it was better to mark all items out:



Did have help:

; it has been great father son project, but recently Cars 2 is more popular, so I am working once he goes to sleep and before he wakes.

Have used my domino to help position rear inner wing panels on the floor panel,


Front inner wings attached to base:


Cut slots in floor for handbrake using my MFS and OF 1400





Have my main outer side panels cut (using a template made of 5mm ply) and my OF1400.  Made some mistakes with that initially.  Even the the guy at Woodcraft warned me to only cut off a small amount of material with the template bit, I did not realize what he meant, second time I took the jig saw around the plywood to leave just 6-8 mm to trim off with the router.  Much easier.  I used the CMS with router attached to round over these large panels where instructed on the supplied build plans.



More to follow later

Sure from memory I think I bought the black clamping part from

http://www.vac-clamp.com/

I bought a carvers vice from  http://www.highlandwoodworking.com/veritascarversvise.aspx

it works well, but can use a fair bit of air, I got tired of my compressor coming on and since I was in the UK, during a festool promotion there, I picked up a vac-sys, which I have to admit works even better.

My plan for very large (heavy) items is to shim up my vac clamp (with suitable thickness plywood) so it suctions at same height as the vac-sys.  The experimentation has been a fun part of the project.

The Vac sys, has definately helped me speed up, and I believe I have most of the wooden components made now.

Venk, you can use liquid putty. It is a very thick primer/thin putty that you can spray on. Normal primers or paints are not the way to do it, they have no filling power.

I think the best way to do it is to use real putty on the entire surface, and sand it, but not down to the wood, just leave a very thin layer of putty on top. It is a technique often used for boats. I grew up in a body shop but we also did boats sometime and the secret of a smooth shiny surface was lots and lots of putty and good sanding. First we used a good quality 2 component filler or polyester filler, and then sprayed it with liquid putty for the finishing touch. The last sanding before the finish spray was done by hand with P800 and P1200 paper, for wet sanding. Make sure you wet sand and not dry because the surface will be smoother.  

If you want a finish that looks like a real car you have to get rid of seeing any wood on the surface because wood will never look as smooth as metal. You must definitely get it sprayed, not brushed or rolled. Might take a couple of layers to get a thick enough coat. Finish with a clear coat of laquer to get the shine. That's how it's done on real cars too.

Thanks for the siters.  I'll start with the clamp and vise, but my sister is going to England next summer so may have a shopping list for her. 

On the Festool vac sys, any problem on getting it work in the US?  Do you need a transformer or just a plug adapter? 

Thanks!

keep the good work up , (I've got a real s3 galvy chassis ) I've been wanting to make one for my 4yr old sone but I've never had the time

That looks good, give us some more detail pics please.

You have done a great job, trim detailing is excellent as is the paint finish. Steering wheel is on the wrong side though

Did you get all the bits from real life toys or self source and build from a mobility scooter or similar?

That's just STUPID GOOD !!! 

I hope your kid has fully comprehensive toy insurance - the first scratch is gonna hurt !

That's a real double take - live to see a side by side with real thing.

To me, that's the sort of work you could easily lease out for photo and video shoots.

That turned out great, I like all the details. The finish looks very good, pretty real if you ask me. Great gift for a kid. Does it have a motor in it?

Kev, you been watching "Despicable Me" again  

aye