How to Make a Pinewood Derby Bus

Print the bus diagram and decide which version of a bus to make. A traditional square-shaped bus is easiest to cut and shape. Trace the basic outline of the bus onto the piece of wood. For a traditional bus, only a few exterior cuts are necessary, such as a diagonal cut near the front of the block for the bus's nose, and small diagonal cuts to make rounding the top and bottom easier.

Place the block of wood into the vice grip. Use the coping or band saw to cut the wood to match the bus diagram. It is okay if the wood looks nothing like a bus yet. The shaping process will finalize the shape.

Use a rasp to round off the corners of the wood to create the bus shape. Most buses have very rounded edges, so it is important to make as rounded of a surface as possible to mimic the look of a real bus.

Sand the entire bus until the block of wood is smooth enough to run a piece of knit fabric over without it catching on any part of the wood. You can also use your face as an indicator. If the wood feels soft to your facial skin, then it is smooth enough to paint.

Paint the bus. Paint the entire block yellow. Allow to dry for one hour, then apply a second coat. Allow the paint to dry for 24 hours. Tape off areas of the bus, leaving areas for windows and the windshield. Spray gray paint over these areas. Allow to dry, then remove the tape. Use acrylic paint to paint the desired wording onto the side of the bus. Use red and white paint to decorate tail lights, headlights and any other detailing on the bus. If you have decals, you can use those instead.

Install the wheels on the bus. Align the axles so that they lay straight in the holes. Glue into place. Allow to dry for 24 hours.

Weigh the bus. If it is close to 5 ounces, then do not add weights. If it is less than 5 ounces, drill a few small holes in the bottom of the bus and push the weights into the holes one by one, weighing after each addition. When the bus weighs just under 5 ounces, glue the weights into place.