Step By Step Instructions
Start by cutting out your three seat components from the sanded plywood material. You can make all necessary cuts in this step quickly and easily using your Dremel Saw-Max tool equipped with an SM500 Wood & Plastic Wheel. Measure and mark your cuts, set your tool at full depth and cut along the marked lines, following them through the notch at the front of the tool. The excellent line of sight on the Saw-Max tool makes precise cuts simple to achieve. In this step you'll be cutting a total of 4 pieces. • One Seat Back • One Seat Bottom • Two Triangular Sides for the Seat
Next, we worked on creating a channel in a piece of 2x4 material. This piece will later be cut in two for the front and rear axle. This channel will eventually hold the axle rod onto which the wheels will be mounted. To create a 1/4" wide channel for our axle rod we made 5 passes through the center of the 2x4. Mount the straight-edge guide onto the Saw-Max, set the Saw-Max depth guide to 3/8". With the SM500 wheel still mounted in your Saw-Max tool, make 5 passes side-by-side, checking your metal rod for a snug fit as you work. You may find it will take you more or fewer passes.
Next, you'll be making several cuts in your 2x4 material which will serve as the frame for your car. Cutting 2x4's with the Dremel Saw-Max tool is simplified with the 2x4 Cutting Guide. For all cuts in 2x4, use the SM600 Wood & Plastic Flush Cutting Wheel, clamp the cutting guide along your desired line of cut, make one cut flush against the guide, flip the 2x4 and complete the cut with a final pass. In this step you'll be cutting: • 2 pieces of 2x4 - 19" long (from the 2x4 with the channel cut on step 2) • 4 pieces of 2x4 - 6 ½" long • 1 piece of 2x4 - 17" long • 1 piece of 2x4 - 40" long
At this point, switch back to your SM500 accessory to use your Saw-Max tool to complete your cuts in the 1x4 material. In this step you'll be cutting: • 2 pieces of 1x4 - 19" long • 1 piece of 1x4 - 17" long
Now it is time to assemble your two axles. First, swap out your cutting wheels on the Saw-Max tool. In this step, mount your SM510 Metal Cutting Wheel onto the tool. With your 48" metal rod clamped or held firmly against a lip on your workbench, cut the rod in half to create two 24" pieces. Lay each piece evenly across the channels of your two 19" 2x4's and hammer into place.
Complete your two axles by screwing the 19" 1x4 material on each to cover the rods. Attach the wheels to the end of each rod and tap the hub cap onto the wheel to secure.
Next, it is time to get started on the main support for the front axle. This support will be key in helping you steer your car. Drill holes for the main bolt at 1/2" diameter into the end of the 40" 2x4 and in the center of the front axle (either axle can be used here). We made three axle holes in the main support to adjust for any rider's size. Finally, drill two 3/8" holes at each end of the front axle through which you'll thread your steering rope.
To assemble the main frame of the car, set your 40" 2x4 across the front and back axles square in the middle. Secure the back end of the 40" 2x4 into place by attaching two 6- 1/2" lengths of 2x4 material at each end of the rear axle. Next, sink a screw into the rear axle through the end of the center 40" 2x4 piece. Secure the front of the 40" piece to the front axle with your 1/2" bolt to allow your car to steer.
Add your seat support about 16" from the rear axle by sandwiching your center 40" frame in between the 17" piece of 1x4 and securing the final two 6-1/2" pieces of 2x4 on top to create a flat level surface for your seat. Next, attach the seat bottom at the center seat support and the rear axle, secure with screws. Attach the back and sides to complete your seat.
Finally, attach the rope for steering. Decorate as desired and ride!
To reduce the risk of injury user must read instruction manuals for all tools used in this project. Wear eye and respiratory protection. Use clamps to support work piece whenever practical.