Orange Falcon Pinewood Derby Car Kit Instructions
Orange Falcon Car Kit
Your car kit should have the following parts:
- Plastic Spoiler
- Plastic Cockpit
- Plastic Hood
- 2 Plastic Scoops
- Orange Paint
- Black Paint
- Silver Paint Marker
- 2 Paint Brushes
- Car block, wheels, axles, graphite and other items (if ordered)
IMPORTANT – READ ALL INSTRUCTIONS FIRST BEFORE BEGINNING TO BUILD YOUR CAR
Note: Shake all paint vigorously for one minute before using.
- You can customize your car by rounding the front as shown with a file or rasp.
- Sand the car block with the lowest numbered sandpaper. You will find the number on the back of each sandpaper sheet. Remove any rough spots and sharp edges with the sandpaper. The block should feel smooth to the touch when done.
- Paint the car block with one thin coat of paint. Rinse the brush with water then dry the brush with a soft cloth.
- Paint the plastic parts with the black paint using the second brush. Note: Feel free to customize your car by painting some of the parts orange. You can also not paint some parts. Rinse the brush with water then dry the brush with a soft cloth.
- Let the paint dry for at least two hours.
- Lightly sand the car block (not the plastic parts) with the highest numbered sandpaper. The block should feel smooth to the touch.
- Give the car and plastic parts two or three more coats of paint. Let dry for at least one hour between coats. Do not sand between coats. Let the last coat dry over night.
- Paint the windshield on the cockpit with the silver paint marker or, if you decided to paint the cockpit orange, paint the windshield with the black paint. Let dry for one hour.
- Glue the scoops on both sides of the car (Adult supervision
is recommended when using super glue). Place the scoops far enough
forward so that they do not interfere with the rear wheels. Hold
in place with a rubber band. Let dry for one hour.
- If you have access to an accurate scale, put the car block and all pieces (including wheels and axles) on the scale. If the weight is less than 5 oz. add coins until you reach 5 oz.
- Glue the other plastic parts on the car using the picture at the top of this page as a guide or be creative and use your own layout. Glue any coins added in the previous step to the block inside the cockpit . Let dry for at least one hour.
- If you are using your own axles be sure to file off the crimp marks and burrs and polish them with #1200 sandpaper. Finish up with a good metal polish.
- Lubricate the axles with graphite by inserting the axle into the wheel then tip the axle so the pointed end is up as shown in the picture. Then pour as much graphite as you can into the space between the axle and the wheel hole. Work the graphite in by tapping and spinning the wheel while adding the graphite.
- If you bought our axle installer, use it to mount the wheels and axles on your car. If not, carefully insert the axles into the slots. They should go in as straight and level as possible. The gap between the wheel and the car body should be a credit card thickness.
- Spin each wheel. It should spin freely for several seconds.
- Weigh your car. If it is over 5 oz, you can remove weight by carefully drilling a few holes part way through the bottom of the car.
Your car is ready to race!