Building a Basic Junior Solar Sprint Car

1
Building a Basic Junior Solar Sprint Car

• Building a solar car can be intimidating the
  first time you attempt it. Watt Watchers of
  Texas has created this very basic car building
  power point to give you a starting point. Part
  of the Junior Solar Sprint program is to design
  the car. After you have figured out the basics
  of building a working car, expand on that
  knowledge by adding different wheels, creating
  different shapes, or testing different
  configurations of the parts. Good Luck.

2
Collect Materials

• You will need
• JSS solar panel
• Wheel and motor assembly
• Foam board and other construction materials
• X-Acto knife or other cutting device
• Glue gun
• Velcro tabs
• 2 Binder clips

3
Building the Car Frame

• Cut out a base that is a 11cm x 33 cm rectangle
• Write front and rear at either end of the
  rectangle on both the top and the bottom

4
Building the Car Frame

• Draw a line 3.5 cm from either end of the base.
  This is where you will attach the axles. Draw
  this line on the top and the bottom of the frame.
• Cut out a notch on either side of this line to
  allow space for the wheel attachments.

5
Building the Car Frame

• At the rear end of the base, draw a line
  perpendicular to the axle line about 4cm in from
  the side. This line should go beyond the wheel
  attachment line.
• Cut out this line so your hole is 1cm wide. This
  space will accommodate the gears.

6
Solar Panel Riser

• Cut a piece of foam board 17 cm x 4 cm
• Draw a line 4 cm in from each end
• Score that line so you go through 2/3 of the
  material. You will be bending along the scored
  line

7
Solar Panel Riser

• Bend at the scored lines to form a U shape.
• Place the riser on the car in front of the notch
  you made for the gear with the arms of the U
  pointing toward the front of the car.
• Glue this riser on the car frame.

8
Solar Panel Riser

• Place the solar panel on top of the car and angle
  it down toward the front end of the car. Shave
  off the arms of the riser to reach your desired
  angle

9
Solar Panel Riser

• Place a 2cm piece of fuzzy side (loop) Velcro
  on top of the riser and at the front of the car

10
Solar Panel Riser

• Place the solar panel on top of the car again,
  making sure the metal leads are at the rear of
  the car. Mark the bottom of the panel where the
  Velcro should line up.
• Attach pieces of scratchy Velcro (hook side) to
  the solar panel on your marks.

11
Front Wheels and Axles

• Put the front wheel and axle kit together
• Create or attach bearings
• Ideas for bearings include
• Cardstock bridge
• Straw
• A paper tube

12
Front Wheels and Axles

• Attach wheel bearings to the line at the front of
  the car

13
Rear Wheels and Axles

• Place the axle through the largest gear.
• Attach bearings and the wheels to the axle.

14
Rear Wheels and Axles

• Line up the gear with the notch you made in the
  frame
• Attach the axle to the frame using the same
  method you used for the front wheels

15
Motor

• Set the motor in the mounting bracket by placing
  the shaft through the large hole and securing
  with a screw.

16
Motor

• Attach the largest gear (from the motor bag) to
  the shaft of the motor.
• Place the motor next to the gear attached to the
  rear wheel assembly so the teeth line up.

17
Motor

• Attach the motor to the car frame making sure the
  gear teeth are lined up.

18
Connections

• Place your solar panel back on the car and
  connect the motor wires by placing the wires
  between the leads of the solar panel and applying
  a binder clip to maintain a secure connection.

19
Finished Basic Car

• Your finished car should run forward and straight
  for the best results.
• Now, expand on your knowledge and design a car
  with style and flair and a bit of solar ingenuity.