- 1). Read the rules included in the pinewood derby car kit and any additional rules given to you by the race organizer. The basic pinewood derby rules state that the car must be less than 7 inches long, weigh no more than 5 ounces and have a minimum of 3/8-inch clearance under the car.
- 2). Focus on a theme for your car that may help guide the design shape or the paint scheme. Some themes that are common include cartoon characters, sports themed cars and Cub Scout troop or den themes.
- 3). Draw some profile designs of what you might want the car to look like on a piece of paper. Many people strive for an aerodynamic design, with a pointed front to the car, but this is not really a factor in the speed of the car. Be creative and imaginative. Once you have decided on a design, draw it to scale on a piece of paper, cut it out and lay it on the derby car block. Trace the design on to the block as a guide for shaping the car.
- 4). Cut and shape the car using a band saw. A medium grit sandpaper is good for smoothing any rough edges. It is best to secure the block in a vise for safety and ease.
- 5). Add weights to the car after you have the shape. You can use anything to weight the car but there are weights specifically designed for pinewood derby cars. You can obtain these at most hobby shops. You will want your car as close to the 5-ounce weight limit as possible. The weight of the car is the biggest factor in its speed. Weights can be added anywhere but keep in mind the clearance requirement if you add them to the bottom of the car. You may need to hollow a space out for this. Weights added to the rear of the car seem to be best for speed. Don't forget to weigh the wheels and axles when you are determining how much weight to add.
- 6). Decorate the body of the car with paint and/or decals. You can design the paint scheme to reflect the racer's interests. Some ideas are to number the car with the racer's favorite number or age, add stickers of the racer's favorite sports team or interests, such as dinosaurs, or include figures mounted to the car, like small soldiers or Lego characters.
- 7). Complete the car by adding the wheels and axles. Use a graphite powder lubricant on the axles after polishing them so they are free of burrs. Clean the inside of the wheels with a pipe cleaner to make sure they spin as freely as possible.
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