How to Build a Solar Powered Vehicle

Our government, especially NASA, has been using solar powered vehicles for years. They are used to explore the surface of the moon and Mars. It makes for a great science experiment that you can do at home and solar-powered vehicles represent 100 percent green transportation because the fuel source is free and unlimited and offers zero pollution.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• 2 Solar Panels (with contacts)
• 2 Wooden Axles
• 4 Screw Eyes
• 2 Large Wheels
• 3 Small Wheels
• 4 Rubber Tires, Black
• 2 Elastic Bands
• Motor Shaft Pulley
• Alligator Clip Test Lead
• Vinyl tubing, 2 centimeter and clear
• Electric Hobby Motor
• Motor Clip, Self-Adhering
• Paper Fastener, Brass
• Sandpaper, Fine
• Foam Board, 24 cm x 7 cm
• Hot Glue Gun
• Glue Sticks
• Scissors
• Utility Knife, Retractable
• Ruler
• Pliers
• Clear Tape

Making the Body

1. Measure the foam board into three sections. Create one piece measuring 20 cm x 7 cm and two measuring 2 cm x 7 cm. Cut them out with the utility knife.

2. Glue the two smaller pieces of foam board together. Glue them on top of the larger foam board at one of the ends.

3. Measure 1 cm in from the center of each side of the smaller foam board you just attached to the larger piece and make a mark. Screw in the eye screws until the holes are nearly touching the top of the foam board.

4. Place one of the axles through the screw eyes.

5. Cut out 5 mm sections from the vinyl tube to use as spacers.

6. Insert one of the wooden axles through the eye holes in the back followed by a spacer on each side then the small tire that was leftover to make the drive train. Put the wheels on the ends of the axle.

7. Repeat step 6 for the front axle (minus the small wheel).

Adding the Motor and Powering the Car

8. Put the small black pulley on the drive shaft of the motor and insert the motor into the clip.

9. Put the elastic band over the back wheel and set it on the drive train (the wheel on the axle).

10. Place the motor close to one of the back wheels on the foam board. There should be no slack in the elastic band. Remove the adhesive on the motor and put into place.

11. 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.

12. 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.

13. Slice the test lead of the alligator clamp into two even pieces. Strip the ends then twist them together.

14. 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.

15. 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.

16. 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.

Tips & Warnings

• If the wheels you chose are too tight for the axle you can sand the axle down until they fit snugly.
• The axle should be parallel to the end of the foam board, adjust the screw eyes if need be.

Resources

• Solar Car Kits for Sale