- 1). Design your Pinewood Derby car. The more complicated the design, the more cuts you will need. Some cuts may require special cutting tools, such as a coping saw.
- 2). Cut the wood block into the desired configuration. Secure the block in a vice so that the wood block doesn't slip while cutting.
- 3). Shape the wood block for appearance and aerodynamics. Use different grits of sandpaper to smooth out the rough edges of the car. You can also use a rasp to smooth edges, round curves, carve notches and add other details to the design.
- 4). Add weight to the car, so that it goes downhill faster. Weights can take the form of pennies, BBs, or any other type of weight that can be secured to the car so that it doesn't fall off. You can also buy specialized weights made for Pinewood Derby cars.
- 5). Paint the car with a primer coat first so that it soaks into the soft wood and leaves a smoother surface to paint on. Spray paint can be used, but you can also brush on paint. Try masking tape to separate multiple colors and to paint straight lines.
- 6). Decorate the car if desired. Some people choose to add decals, pieces of toys, bumpers, chrome, and other realistic touches. Keep in mind these additions will add to the total weight of the car.
- 7). Add the axles and wheels. Inspect the axles for flaws such as casting burrs and remove them with a file or sandpaper. Such burrs restrict movement of the wheels. Also sand the surface of the wheels and lubricate them before attaching them to the axles. Carefully glue the axles in the pre-cut slots so that wheel movement is not restricted.
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