Making the Wheeled Body
Step1
Use your ruler and measure out the foam board into three different sections. Make two of them 2 cm by 7 cm and the other 20 cm by 7 cm and then cut them out.
Step2
Combine the to two smallest pieces by gluing them together. Put glue onto one side of this assembled piece and affix to one of the ends of the larger piece of foam board to make the rear of the car.
Step3
Insert two eye screws into the layered foam board by measuring 1 cm in from each side. Put the screws as far as they will go until the eye hole touches the foam with the hole facing toward the sides and not the back. Put a wooden axle through the eye holes to check to make sure they are even; adjust until they are. Add a drop of glue to the foam and eye screw where they meet.
Step4
Grab the wheels and place a rubber tire on all of them except one small wheel.
Step5
Cut out 5 mm sections from the vinyl tube to use as spacers.
Step6
Put together the rear axle by inserting one of the wooden axles through the eye holes then putting a spacer on both sides followed the extra small wheel (this is the drive train). Insert the wheels then repeat the entire process (minus the extra wheel) for the front axle.
Motor and the Power
Step1
Put the small black pulley on the drive shaft of the motor and insert the motor into the clip.
Step2
Put the elastic band over the back wheel and set it on the drive train (the wheel on the axle).
Step3
Position the motor on the foam board close to one of the back wheels. Make sure there is no slack in the elastic band. Mark the spot then remove the adhesive from the clip and set it in place.
Step4
Look at the back of the solar panels and remove the nuts, washers and metal bars. Bend one of the ends of the metal connecting bar so it looks like a "Z" but with a straight middle.
Step5
Connect the solar panels together with one of the connecting bars connecting one end to the positive contact of one panel and the negative on the other. Secure the bar into place with the nuts and washers tightening until just snug. Add a piece of clear tape over and around the crease.
Step6
Slice the test lead of the alligator clamp into two even pieces. Strip the ends then twist them together.
Step7
Put one end of the bent connecting bar on the threaded metal contact. Loop the test leads bare ends over the contact and screw in a nut slowly until the wires are secure.
Step8
Make a slit through the foam board just in front of the electric motor and about 1/4 inch to the side. Put the other end of the bent metal connector over the slit and slide the brass fastener through the hole in the connector and the slit in the foam board. Turn the car over and open the fastener until the arms are flush with the foam board.
Step9
Put the solar panel (as well as its support) at an angle with the body and affix the lower panel to the foam board then connect the wires to the terminal using the alligator clips.