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How to Build & Design Aerodynamic Wooden Cars

Aerodynamics is a complex subject, crossing the boundaries of several scientific disciplines to arrive at shapes that are, at best, a compromise of mechanical necessity and aero optimization. However, by following a few basic principles and guidelines, even the novice engineer can design and build a fairly aero-efficient wooden car. It all starts with making the car's profile as small as possible and ensuring that what air does pass over it moves as quickly and as unimpeded as possible.

Things You'll Need

Carbon transfer paper
Hand saw, coping saw and/or jigsaw
Basic woodworking tools
Assorted sandpaper

Instructions

Designing the Car
- 1
  Draw out a side-view basic "skeleton" of your car's required mechanical components (including the wheels, axles and CO2 cartridge if desired) in exact 1 to 1 scale. The measurements must be exact. Trace around the provided wood block (if you have one) and wheels when you can. All of the car's measurements will be based off the mechanical component location, so precision here is critical.
- 2
  Draw a line from the bottom of one wheel to the bottom of the next; this will represent your "ground" line. Measure 1/8 of an inch up from your ground line and draw another line parallel to it several inches past the wheels. This represents the bottom of your chassis.
- 3
  Measure the wheelbase of your car, divide that by three and make a mark of exactly that distance in front of the front edge of your leading wheel. This represents the front bumper of the car. Divide the wheelbase by four, and add that distance to the rear axle centerline in the same way.
- 4
  Measure 1/8 of an inch over the highest point of your wheels and CO2 cartridge and make a reference mark. Make a mark 1/8 of an inch over the intersection of your bottom chassis line and front bumper line.
- 5
  Make a mark above the intersection of your bottom chassis line and rear bumper line equivalent to 2/3 the distance of your car's rear-most high point from the ground line. This will be the CO2 cartridge in a CO2 racer, the top of the rear wheel otherwise.
- 6
  Play connect the dots with your reference marks to end up with a wedge-shaped outline that follows the mechanical contours of the car.
- 7
  Repeat this procedure with the top and frontal views of the car.
Building the Car
- 8
  Transfer your side, top and front view drawings (now known as the orthoscopic layout) to your wooden block with carbon paper. Start with the side view.
- 9
  Cut the excess wood away with your saw of choice.
- 10
  Flip the car over so the flat bottom faces up, and transfer your top-view onto it with carbon paper. Cut the excess wood away.
- 11
  Compare the frontal view of your car to the design and trim away wood with the appropriate tool where indicated. There will likely be no flat surface upon which to trace your design.
- 12
  Smooth the entire car out with 80 grit, 250 grit, 500 grit and finally 1000 grit sandpaper. Install the mechanical components and paint the car.

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