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Chassis

Mark wing/body line on both sides of block with template "A", setting the rear of the template 3/16" from the squared end of the block. (The rear wings stop ahead of the rear of the body.) Ensure the markings are aligned on each side.

Locate the wheel centres, Use a protractor to make 2 3/4" diameter wheel well openings (radius 1 3/8"), and draw the rest of the wheel well opening curves from the blueprint.

Marking Cut Lines

Drill wheel wells 3/4" deep with 2 3/4" Forstner. Test fit a wheel, if proud of the sides, go 13/16" deep. (Scale diameter for the rear wheel well is closer to 3".)

Drill Wheel Wells

Drill 5/16" holes for wheel retaining pins.

Check Wheel Fit

Router out the final shape of the wheel wells.

Router Wheel Wells

Set band saw opening to take the width of the block. Check its blade guides and ensure that the blade is perpendicular to the table. First cut the rear wing, cutting along the top of the pencil line from the back moving very slowly around the curve of the rear wing to avoid a slightly twisted blade going off in its own direction. After reaching the 90 degree corner at the front of the rear wing, back out of the cut and cut the front wing, starting at the front end. Again cut along the top side of the pencil line.

Saw Chassis from Block

Use the router table to take out a notch a 1/4" deep, by 13/16" in, under the wings all along each side. Then use it to take a 1/2" deep cut in front of front wheels under the chassis. And then to cut 3/8" deep across under rear of chassis to rear wheel well.

Router Table

Pop on the store bought wheels and voila, a rolling chassis.

Rolling Chassis



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