Basic Solar Car Construction Follow these instructions to create a basic solar car. Once you are familiar with the elements of solar car construction, then you will be able to modify the design to improve the performance and look of your solar car. Basic solar car parts Step 1. Build the base of your solar car. First, we will begin by constructing the base of the car. (The wood blocks will be on the top, and the screw eyes will be on the bottom where the axle will attach in Step 2.)

• Corrugated plastic sheet for body • Two dowels for axles • Two wood blocks (for attaching screw eyes) • 4-5 screw eyes • 4 wheels • 4 tire rings • 1 2V (or 1.5 V) solar module • 1 DC motor • 1 motor clip (stick-down motor holder) • 1 bushing (connects smaller gear to drive shaft) • 2 gears (one small, one large) • Plastic spacer-tubing (4 pieces)

Attach two screw eyes to the plastic base. Allow the screws to just break through the other side. Hold a wood block in place as you continue to screw the screw eye through the plastic and into the wood block. Repeat for the rear end. Note: All screw eyes should be facing the same direction when finished.

 

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Step 2. Build the front and rear axles. The spacers are small pieces of plastic tubing that are used to stabilize the axles.

Step 3. Attach wheels and gear onto the axles. We are going to make a “one-wheel drive” vehicle. (You also can use a pulley in place of the gear.) We will build a gear drive system in this exercise. Slide the black O-rings onto each of the four pulley wheels. Attach the large gear to one of the rear axles. Then slide each of the four wheels onto each axle. If the gear and wheels do not slide on with a reasonable effort, use some sandpaper to gently thin the dowel (be careful not to over-sand the axle or your wheel will fall off).

First, slide one spacer on one end, then insert dowel (axle) through both screw eyes, and then slide the other spacer onto the opposite end. Leave space to attach wheels and gears (or pulleys) in Step 3.

 

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Step 4. Attach the motor and small gear. Insert the small DC motor into the bulldog clip. The bushing and small gear may already be attached to the DC motor in your kit—if not, attach them as shown. Now attach the motor and clip to the rear of the solar car such that the small gear on the motor engages with the large gear on the axle. Notice that there should be some adhesive material on the bottom of the bulldog clip. If it is no longer sticky, then add some new tape, Velcro, or “tacky” material to keep the motor in place. Step 5. Attach solar module. Attach the solar module to the motor as shown. Be sure that your wires and module do not interfere with the operation of your solar car.

 

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Step 6. Test your car! If there is sun outside then we can test the solar cars outdoors. Otherwise, we can test indoors using a shop light. Is your car moving forwards or backwards? Did you notice problems with the performance of the solar car? What do you think happened? How can you improve upon your design?

Figure  1.  This  version  of  the  engineering  design  process  is  from  "Engineering  is  Elementary"  through  the  Museum  of  Science,  Boston.