The Build

Well here we are, some 2 years or so later but we have started the build.

The original mower was stripped down and all unnecessary parts sold or scrapped! In the photos below you can see that the only parts I have kept are the plastic bonnet, the plastic combined seat, mudguard and transmission tunnel, the seat support panel and the deck.

Unfortunately the deck had some serious rot in it, just behind the engine cut out so I had to weld in some new metal. Note that the replacement material used was of the same thickness as the original; this is important as a failure to comply with this BLMRA rule would mean it failing scrutineering.

Here are all of the salvaged parts loosely assembled to show what it will look like when finished.

Even though the metal deck on the Lawn Ranger is quite strong with little flex, I decided that it needs some additional strengthening. The 2 areas are, lengthwise bending in the middle due to the loads that will be inflicted on it when racing and footplate deflection. To overcome these problems I am building a metal tube framework into the deck. This will, when finished, give additional longitudinal support and also provides location points for triangulated support framework at the front and rear of the footplates. In the picture below you can see that I have just started on the framework.

The general Group 4 build guidelines published by the BLMRA allow you to lower the footplates and to make them wider to give support for side impact rails. I have chosen not to do this as the side impact rails will be self supporting and will not be used for foot placement. (More on this later).

Building strong tubular steel framework relies a lot on the jointing of the tubes and 'fishmouth' joints need to be cut. To assist in this I purchased a tube notcher, a photo of which you can see on the Tools page.

Some more frame bits added. You can also clearly see the deck that I had to replace as it was rotten. A couple of other repairs to the engine mounting holes were also necessary.