- 1). Cut one 8-inch by 3-inch piece and two 3/4-inch by 3-inch pieces from the foam board.
- 2). Glue the two smaller pieces of cut foam board horizontally onto each end of the 8-inch by 3-inch piece for reinforcement.
- 3). Screw the screw eyes through the two end pieces of foam, about 1/2-inch from the edges of each piece. These will serve as the wheel mounts. The eyes of the screw eyes should be facing the shorter edges of the end pieces.
- 4). Slip the axles through the screw eyes so that they are parallel to the short ends of the foam base.
- 5). Slip a vinyl tubing spacer followed by a large rubber tire onto the left sides of the axles and onto the front right side. Add a vinyl spacer followed by a drive pulley and a large rubber tire onto the right rear axle.
- 6). Test the car to ensure that it rolls in a straight line. If it does not, adjust the axles accordingly.
- 7). Push the motor shaft pulley onto the motor shaft.
- 8). Stretch the rubber band from the drive pulley on the right rear wheel to the motor shaft pulley on the motor. Position the motor so that the rubber band is pulled taught but not stressed and use the motor clip to stick the motor to the foam board at this location.
- 9). Connect the two solar cells together in an array by creating a contact between the two positive and negative contact points. This can be done by soldering a copper wire to each of the poles if you do not have cells with screw-down contact points. If you do have cells with screw-down contact points, screw a metal connection plate between the contact points. Tape the cells together for extra strength across the the middle and then tape a 3-inch piece of clothes-hanger wire across the gap so that is is equally extended onto both cells.
- 10
Cut the alligator test lead in half and strip the wire ends about 3/4-inch. - 11
Bend the ends of the 3-inch pieces of clothes hanger wire at a right angle. Each bent end should be 1/3-inch. Secure one end to the bottom of one side of the solar cells using the screw down points, solder or an adhesive. - 12
Connect one alligator clip to a positive terminal on one solar cell and the other to a negative terminal on the other using solder or screws. - 13
Place the solar cell on the foam board so that the clothes-hanger wire leg rests next to the motor and the bottom of the solar cells is against the surface of the foam. Tape down the part of the cells touching the foam. - 14
Connect the alligator clips to their respective terminals on the motor then place the car in bright sunlight.
next post