This project was completed for a soap box derby race held in St. Louis, MO. There are two frames to the design, one that supports all the aesthetics of the car and one that supports all the mechanics of the car. The car was built on two frames so that both aspects could be worked on in parallel and then joined together to form one piece of finely tuned mechanical artistry. This instructable will mainly cover the process of building the aesthetics of the car. The whole project from conception, to funding, to building, took one month for a team of five persons to complete. Break neck pace... pressure builds diamonds.
The three photos included in this step depict the final product on race day as well as a concept sketch of the design before anything was built.
Step 1: Sourcing Parts and Framing
Sometimes the best place to find cheap materials for a build is in a dumpster (see photo 1)!
Outside of dumpster diving, rectangular steel tubing was acquired from a metal supplier and welded to provide the frame for the mechanical portion of the car. An assortment of 1" x 1", 1" x 2" and 2" x 4" lumber was purchased from Home Depot to build the frame for the aesthetic portion of the car. The aesthetic frame was built around the mechanical frame and bolt holes were drilled to lock the frames together when so desired (see photo 2).
Once the frames were complete, work on the muscle man (Hanz) began by building quick and dirty mock-ups attached to the aesthetic frame (see photos 3 & 4). These mock-ups were built using PVC tube, Duct Tape, pink insulation foam core (see photo 5) and card board. All of these parts can be purchased at Home Depot or found in the trash. The goal with the foam core and PVC was to create ribbing that a lighter weight skin material could be stretched around to develop the general shape of Hanz's body.
Please note that a full parts list with quantities is not included as this project and any similar ones are so custom that there is not much value in including one. Instead, the parts used are discussed but not the actual quantities.
The parts used for the aesthetic portion of this build include:
1" x 1", 1" x 2" and 2" x 4" Wood Lumber
PVC Tubing and connectors
Tools used include: