1. ELECTRIC VEHICLE PROJECT CAR BUILDING PROCEDURES BY: PIERRE PEASHA CENTENNIAL HIGH SCHOOL BAKERSFIELD, CA

2. PARTS LIST MATERIALS LIST Board or Sticks (Chassis) Electric Motor 2 Steel Axles Front Wheels Rear Wheels Straws Gear – Motor Gear – Axle Battery Holder Alligator Clips Batteries

3. PARTS LIST GEAR FONT PAINT STIR STICK

4. REQUIRED TOOLS Ruler or tape measure Pencil Utility Knife Scissors Hot Glue Gun - glue Soldering Iron - solder Pliers (needle nosed pliers) Sand paper Small Saw (or device that allows crosscutting of paint sticks)

5. MAKING THE CHASSIS CHASSIS MATERIALS Many options are available when choosing the material for the chassis. In this example a large paint stir stick acquired free from the local hardware store is used. Other options are: Wood Yard Stick Balsa Wood FOUR EXAMPLES ARE SHOWN ABOVE

6. MAKING THE CHASSIS: 3 STEPS 1. Using a paint stir stick, measure 8” from either end. With a pencil draw a line that is 90° from the edge. Cut on the line leaving an 8” long chassis piece. A wood yard stick from the local hardware store can be used for this. THREE EXAMPLES ARE SHOWN BELOW

7. MAKING THE CHASSIS, CONTINUED LAYOUT FOR AXLE PLACEMENT 2. Choose which end will be the front of the chassis. From the front end measure 1 ½” and draw a line across the chassis 90° from the edge. 3. From the back of the chassis draw a line across that measures 1” from the end. These lines will define where to glue the straws for the axles. If you are using the wood yard stick the measurements are conveniently already in place.

8. GEAR SELECTION AND ASSEMBLY: 5 STEPS GEAR SELECTION 1. Using the part package called Gear Font, detach Gear I (40-tooth, 1/8” bore). This gear will be the drive gear and attach to the axle. 2. Using the same Gear Font part package, detach Gear G (20-tooth, 2 mm bore). This gear will be the pinion gear and attach to the motor.

9. 3. Extra plastic sometimes needs to be removed from the gears so they can run smoothly. Complete this process by trimming with a utility knife or sanding with abrasive sand paper. 4. Press Gear I (40 tooth, 1/8” bore) on one of the steel axles. 5. Press Gear G (20 tooth, 2 mm bore) on the electric motor. GEAR SELECTION AND ASSEMBLY, CONTINUED

10. REAR AXLE ASSEMBLY: 3 STEPS 1. On the axle with Gear attached, press one of the rear wheels on the same side as the gear. 2. Cut a piece of the straw equal to or slightly wider than the chassis material. This will act as an axle holder and spacer. Slide the straw onto the axle. 3. Press the remaining rear wheel on the other side of the axle.

11. FRONT AXLE ASSEMBLY: 2 STEPS 1. Cut a second piece of straw for the front axle. 2. Press one front wheel on the axle, slide on the straw and press on the other front wheel.

12. ATTACHING THE AXLES TO THE CHASSIS: 4 STEPS 1. Locate the lines drawn on the bottom of the chassis. Use these lines to reference the location of each axle. 2. Using the hot glue gun, bead a line of hot glue to the chassis next to the line. 3. Glue the straw to the chassis.

13. ATTACHING THE AXLES TO THE CHASSIS, CONTINUED Be extra careful to glue the straw perpendicular to the side of the chassis otherwise the car will not drive straight. 4. Then, add extra glue to strengthen the bond between the straw and the chassis.

14. ATTACHING THE AXLES TO THE CHASSIS SLIDE THE AXLES INTO THE STRAWS

15. ATTACHING THE MOTOR TO THE CHASSIS TEST FIT MOTOR AND MOTOR LAYOUT Place the motor on the chassis so that: Gear G (motor) fits directly and engages Gear I (axle) The two gears engage (mesh) The vent holes point up Motor connecting terminals do not rub rear wheel Motor shaft is parallel to the rear axle Using a pencil, make a small mark on each side of the motor for hot glue placement.

16. ATTACHING THE MOTOR TO THE CHASSIS GLUING MOTOR IN PLACE Using the glue gun apply a bead that covers the square drawn on the chassis for motor placement. While the glue is still liquid, place the motor. Hold until the glue cures or cools. Be careful with this step not to obstruct the motor vent holes or get glue in any way into the motor. Take care to keep the motor properly placed until glue cures or cools.

17. SOLDERING ALLIGATOR CLIPS TO BATTERY HOLDER Each alligator clip has a small hole for a wire to slide through and tabs to clamp down the insulation on the wire. (see right) Slide the bare wire through the hole so that the insulation is located between the tabs on the alligator clip. (see left)

18. SOLDERING ALLIGATOR CLIPS TO BATTERY HOLDER CLAMP WIRE WITH TABS Using a pair of pliers, bend the tabs on the alligator clip around the insulation securing the wire to the clip. Be careful not to break alligator clip. SOLDER WIRE TO ALLIGATOR CLIP Turn the alligator clip over and solder the bare end of the wire to the clip.

19. ATTACHING THE BATTERY HOLDER TO THE CHASSIS: 3 STEPS ATTACH BATTERY HOLDER 1. Use the glue gun to attach the battery holder to the chassis. 2. Attach alligator red wire (positive) to motor. 3. Attach alligator black wire (negative) to ground (chassis).

20. FINISHED ELECTRIC VEHICLE