42082 D model – Heavy Forklift Truck

An alternate model of the 42082 as a Heavy Forklift Truck, featured steering, rear oscillating suspensions, fake engine, opening engine, battery bay and doors, raising and tilting fork, adjustable fork width and tilting maintenance cabin. With Building Instructions.

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Direct purchase of the instructions

Context

After releasing the 42082 Model C – Wheel Loder, it had a nice success on Youtube and Rebrickable but some people complained about the fact there were only 2 motorised functions (plus some manual) and the use of only  1786 parts. Therefore, I wanted to create a new alternate model for the 42082 which would use more parts and with more functions. I consequently decided to work on a heavy forklift truck in the beginning of February, based on a Kalmar Brand Design.

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Functions

As described above, I have tried to put the maximum of functions in this creations, with some manual (steering, suspension, openable elements) and some other motorised (fork). The first one is the steering on the rear axle, the hand of god is placed on the top and passes through the motor axle with a 20t simple bevel, then operates a rack and pinion with Ackerman geometry. The rear axle has also a small oscillating suspensions by using the axle of rotation for the steering. End-stops prevent the wheels to touch the mudguards. The fake V6 engine is located on the front and is visible after tilted the cabin. It is connected to the front axle with a central differential.

All motorised functions are powered by a L-Motor located underneath the battery box at the rear and drive the 4 gearboxes with a bevel gear inverted underneath (same principle as official 42082) to create the two way of rotation needed. Each driving ring is connected then to a function, and many gearing and axles connect the functions :

  • Tilting fork
  • Raising fork
  • Adjustable fork width
  • Tilting maintenance cabin

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The tilting of the fork is operated by two linear actuators placed each side of the fork. The raising of the fork is a bit more complex : the boom of the fork is composed of a frame and a sliding section plus the fork which can move inside, the fork is attached to the chassis underneath by passing to the top of the sliding section. Then, the second section of the boom is raised using racks and pinion though the two axles with U-join which make move the fork consequently (this is the same functioning as on the 8416). Of course the reachable position in height for the fork highly depends of the number of rack in the 42082 set which is not bad but not so high.

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I have placed two axles with U-join firstly because it enables to not hide the road from the cabin for realistic point, and second because it enables to handle more torque by dividing the torque on each axle. You can see on the picture underneath that there are two clutch gears in line in order to have enough friction to raise the fork but not too many to secure the play (there is no worm screw in the 42082). You can see also the complex path of the string, as it is attached to the both side of the fork and is 300cm-length, I had to deal with this length (I did not want to cut it to enable re-building of the main model of the 42082). Therefore I have create a drum to wind the string and also adjust the position of the fork on its ends by rotating the drum.

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The last function on the fork is the adjustable fork width, which can be done only in lower position. It is explained by the fact that there are not possibilities to control the small linear actuators with moving fork without sliding gear or other rope or embedded motors. When the fork is on its lower position, the gears which connect the mini-linear actuators are connected to the two double bevel gears which enables to operate the width. The main axle is stuck out in order to centre the fork gearing for avoid cracking.

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The last motorised functions is the tilting maintenance cabin, which is operated by a mini linear actuator underneath the cabin. It enables to made the operation of maintenance on the real one and to discover the V6 engine here.

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Design

The idea was to propose a creation with many functions but also a nice look to play with it. In this way, the rear trunk can be opened to reveal the battery box and are held in place thanks friction linkages. The small dark bluish grey panel on the front can also be opened to see the drivetrain. To finish with the design functions, the doors of the cabin can be opened. The model is also highly detailed with lights and mirrors, bars, detailed cabin with seat, dashboard and levers, but also sturdy in order to have a good playability.

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Pictures and Video

Building Instructions

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The release of my previous alternate model for the 42082 told me that fans like a lot comprehensive building instructions for alternate model, therefore, after month of works, I can propose you the complete building instructions. The building instructions are composed of 360 pages,  step by step pages computer rendering which looks like official Lego one, at the price of 15€. You can note that we have increased the quality of the instructions again, by using new features (buffer exchange for wire and rope, white edge on black parts, rotate icon, gear stress picture). Here is the complete bill of material in picture file :

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But you can also checked it on rebrickable and export in whatever format you want :

Want to know if you can build the 42082 Model D Forklift Truck ? The Forklift Truck has been indexed to rebrickable, check it !

You can buy the instructions with the following button for 15€. You can also buy other building instructions and get an automated discount, for instance my 42082 C model and/or E model. You will get 15% off for 2 PDF, and 20% off for 3 PDF on the total). The automated discount is also available for all the instructions for sale on nico71.fr.

42082 Model D – Forklift Truck

42082 Model C – Wheel Loader

42082 Model E – Offroad Truck

Price list for example :

  • Model C + Model D or Model C + Model E = 21.25€ instead of 25€ (save 15%)
  • Model D + Model E = 25.5€ instead of 30€ (save 15%)
  • Model C + Model D + Model E : 32€ instead of 40€ (save 20%)

 

After your payment, you will receive the link to download the instructions by email. Please check the spam box and be patient to receive it. If you have trouble to download your copy of the PDF after payment or open the document, do not make a paypal dispute, please contact me using the contact form. The link to download the instructions expires within 24h. Contact me if you have lost your instructions. Note that you can print it, but not copy or distribute. Thank you for supporting my work 🙂

You can see some example of the page of the instructions :

Please note this building is rather complex and composed of many moving axle and gears and drivetrain. Please pay attention to not stress the gearing, axles and bushes, and bracing correctly each, in order to have free rotation on every axle to avoid problem of functioning. Having a battery in good health is highly recommended.

(11) Comments

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    Hi Nico,
    I bought the intruction some month ago and now the project is finished. The model looks great, the functions and the playability are great, too! It looks very realistic. Building was not too easy, you should have some Lego Technic experience.
    The instruction is worth each cent, great job. Thank you very much for enabeling us to build the fork lift.
    Best regards from Bavaria,
    Martin

    completed the build, found the body very good and the opereating levels al;l together very smart, the lifting, tilting and opening of the engine compartment very good, the sideshift weak.

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    Thank you for your comment ! Feedback appreciated. I will contact you directly because I can not find which parts do you talk about (as there are multiple revision on the file, it may not be the same page number).

    Hello,

    Just finished this weekend the build.

    Great build By the way.

    Two things can be better :
    – Step 4 page 93 I used one 4211779 instead of the 1×2 4515184 is thougthend the axe for the motor
    – Changing battery is a hell of a nightmare when the build is completed.

    Great work, and totally worth the 15 € !

    Bye

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    how many pieces does the forklift consist of, and how long will it take to build? Thanks

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    Hello David, thanks your commands, you will not need any more parts that the parts in the 42082 🙂

    Brilliant work! Well done!
    Quick question does the model require any additional pieces? Does this also apply for Wheel Loader?
    Thanks

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