Introduction
For a long time I have wanted to build an RC car completely from scratch, but never quite had access to all of the tools required to do it by hand or been able to justify the cost of using rapid prototyping methods. After taking part in the Intel IOT Invitational and the Mediatek Linkit One challenge I found myself with a whole bunch of Amazon and Shapeways vouchers, so I decided it was time to make the dream a reality.
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The goal of this instructable is twofold, for anyone who wants to replicate my project exactly, I will provide all of the files (including editable models) and instructions to do it, but more interestingly, I will try and explain my choices and processes so that anyone can take what I have learned and use it to build their very own one-of-a-kind RC car, based on mine, or straight out of their own imagination.
Design Choices
The first step when starting a project like this is to determine your goals and your limitations, these were mine, yours may be different.
Design Goals
- Build as much as possible myself
- Design something unique
- Use lots of metal in the design (I like how realistically heavy RC's drive)
- Solid rear axle hot-rod
- Resiliant enough to actually drive (not a shelf queen!)
Design Limitations
Cost: I wanted to spend as little as possible (some further notes on that below)
Time: I wanted to get it done in 80 days for the 3D printing competition, this was a great motivation to keep working hard on it. The 3D modelling was by far the most time consuming.
Available Tools: No metal working facilities, hence why I chose laser cutting and carefully designed around having to do anything other than drilling and tapping afterwards.
Available Software: I am familiar with Solid Works, but now that Autodesk Fusion 360 is available free to hobbiests I used this as a project to learn on. I can't recommend it enough!
Potential Cost Reductions
![Model Model](/uploads/1/2/4/8/124865959/913719941.bmp)
I was fortunate enough to be able to fund almost the whole project with vouchers I won from various Instructables competitions, but this means that my choices would not universally be the cheapest options, here are some ideas if cash is tight.
- Design around a readily available body
- Build the body by hand out of Styrene or Wood
- Print the body in pieces on a hobby 3D printer
- Use cheap motor/esc/servos/wheels from an old RC car
- Print the profiles on paper and cut Aluminium parts by hand on a bandsaw/scrollsaw