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Cautionary and Warning Statements
•
This kit is designed and intended for educational purposes only.
•
Use only under the direct supervision of an adult who has read and understood the instructions provided in
this user guide.
•
Read warnings on packaging and in manual carefully.
•
Always exercise caution when using sharp tools.
•
Safety glasses required when soldering.
Soldering Iron Safety Tips
• Always get permission from an adult before using a soldering iron.
• Be sure to read and follow all of the manufacturers instructions provided with your soldering iron.
• Never touch the element or tip of the soldering iron.
• Always return the soldering iron to its stand when not in use.
• Turn unit off or unplug it when not in use.
If you are competing in the Junior Solar Sprint competition, we encourage you to create your own design. Refer
to the official Junior Solar Sprint rules when designing your vehicle to meet those specifications. This user guide is
intended for those not participating in the JSS competition and represents one of many ways to build the vehicle.
Materials Included
The solar panel and motor are official parts required by the Junior Solar Sprint competition.
• Solar panel blank (10-1/2" x 5" plastic-coated paper)
• 2 balsa wood sheets (10-1/2" x 4" x 3/16")
• 2 alligator clips
• 2 rear (wide) wheels
• 2 front (narrow) wheels
• 2 wide rubber bands
• 2 screw eyes
Items Required (not included)
• Soldering iron and solder
• Hobby knife or coping saw
• Cool-melt glue gun and glue slugs
• Sandpaper
Making the Chassis
1. Using a No. 2 pencil, draw Line A down the center of a balsa sheet
(Figure 1).
2. Turn over the balsa sheet. Draw Line B 3/4" from one end of the
sheet (Figure 2 on the next page).
Ray Catcher Sprint Deluxe User Guide 58963 V0513
Ray Catcher
Sprint Deluxe
• 4 nylon spacers
• 2 steel axles
• Plastic gear font
• 2 No. 14 rubber bands
• Two-cell AA battery holder
• Motor 280
• Ray Catcher Solar Panel (shared item)
• Needle-nose pliers
• 2 C-clamps
• Ruler
5-1/4"
User Guide
58963 V0513
5-1/4"
Figure 1
1
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Summary of Contents for pitsco RAY CATCHER SPRINT DELUXE
- Page 1 • Two-cell AA battery holder • 2 wide rubber bands • Motor 280 • 2 screw eyes • Ray Catcher Solar Panel (shared item) Items Required (not included) • Soldering iron and solder • Needle-nose pliers • Hobby knife or coping saw • 2 C-clamps • Cool-melt glue gun and glue slugs • Ruler • Sandpaper Making the Chassis 5-1/4" 5-1/4" 1. Using a No. 2 pencil, draw Line A down the center of a balsa sheet (Figure 1). 2. Turn over the balsa sheet. Draw Line B 3/4" from one end of the sheet (Figure 2 on the next page). Figure 1 Ray Catcher Sprint Deluxe User Guide 58963 V0513...
- Page 2 7. Using a cool-melt glue gun, run a small bead of glue along one of the 4" edges of the panel support member and attach it firmly at Line A (Figure 3). After it is in place, run an additional bead of glue on each side of the joint between the chassis and the support member. Wheels, Gears, and Axles Installing wheels and gears on axles can be difficult. The gears and wheels should fit snugly to the axle and provide power to the wheels. Your teacher has troubleshooting tips on what to do if the gears and wheels are not snug. Rear Axle Assembly 1. Deburr the axles by brushing the ends against sandpaper. This makes it easier to push the axles into the wheels. 2. Detach Gear I from the gear font. Using a sharp knife, carefully remove any plastic flashing between the gear teeth. 3. Place the gear on a table. Insert one of the steel axles into the gear. Slide the gear 1-7/8" from one end of the axle. It should be 3-3/8" from the other end of the axle (Figure 4). 4. Slide two nylon spacers onto the axle, one on each side of the gear (Figure 4). Figure 4 5. Place one of the rear wheels flat on a table. Keeping the spacers in place, insert one end of the axle into the wheel. Slide the axle into the wheel until it is flush with the opposite side of the wheel. 6. Lay the other rear wheel flat on the table. With spacers still in place, slide the free end of the axle into the wheel until it is flush with the opposite side of the wheel. 7. Stretch a wide rubber band around each of the wide wheels. These act as tires and provide traction for your vehicle. Ray Catcher Sprint Deluxe User Guide 58963 V0513...
- Page 3 Gear F directly on top of and engages Gear I (Figure 5). Be sure not to block the vent holes with glue. Hold the motor in place while the glue cools. 6. Apply another bead of cool-melt glue behind and in front of the motor (Figure 5). This will keep the motor in place if the vehicle comes to a sudden stop or crashes. 7. If the motor dislodges, use the tip Gear I of the glue gun to soften the glue on the chassis where the motor was. Add a small amount of glue and reattach the motor as you did Figure 5 – In this illustration, Gear F engages Gear I. before. Ray Catcher Sprint Deluxe User Guide 58963 V0513...
- Page 4 1. Using a cool-melt glue gun, run a small bead of glue on the top, extreme front of the chassis. Allow the glue to cool. This will provide a ledge on which the solar panel or solar panel blank can rest. 2. Run another bead of glue along the front edge of the chassis to provide a bumper for your vehicle. 3. Position the solar panel blank on the chassis so it rests at the front of the vehicle and on the panel support member. The blank is used to show the position and effect of the solar panel on the vehicle as you test your vehicle with the battery pack. When you are ready to do a solar test or race, use the solar panel that your teacher provides and replace the blank with it. 4. Stretch one of the No. 14 rubber bands around the front of the chassis and the solar panel blank. Stretch the other No. 14 rubber band around the chassis and panel blank and position it at about the center of the panel blank. 5. Connect the battery pack’s alligator clip with the red lead to the motor terminal that has a round dot. Then connect the alligator clip with the black lead to the other motor terminal. Optional If you are running your car on a guided wire or fishing line, use the screw eyes to keep your car in line. Insert the screw eyes into the bottom of the chassis, one toward the front of the vehicle and another toward the rear, centered between the sides and in-line with the direction of travel. P.O. Box 1708 • Pittsburg, KS 66762 www.pitsco.com Tolll-Free Orders 800-835-0686 Ray Catcher Sprint Deluxe User Guide 58963 V0513...
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