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Registration Date: 8th-Sep-20
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Additional Info About KensRedZed
Favourite Slot Car:
Chaparral 2D
Favourite Track Type:
Routed wood
Favourite Motor Sport:
Le Mans - CanAm
KensRedZed's Most Liked Post
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RE: Scratch building an aluminum chassis 11
Thread Subject Forum Name
Scratch building an aluminum chassis Scratch Building
Post Message
I mark the area around the guide hole with a large permanent marker. Then set my callipers to 1.65mm and scribe a line around the guide hole. This is my safety zone. Cut too close to this line and the chassis is scrap. I've already scrapped several chassis that were 95% finished. Oops.

Take your time with this area. I use a combination of bandsaw for rough cuts, and a quality hand file to finish it off.


I install a sample body post at the rear of the chassis and mark around it. Then draw lines for the bandsaw. The sanding disk is used to give it that "store bought" look.


Every once in a while I'll substitute a Slot.It guide for an NSR. The NSR guide can turn a bit more when the guide is very close to the axle.


Chassis is assembled. The motor is glued in with 5-minute epoxy. This method of fastening the motor freaks a few slot car people out. But I'm an old RC aircraft guy and this works so well, that a lot of members in my slot car club now glue motors in too. Water flows downhill. It's hard to fight simplicity. It's now a well proven method.


Body posts are attached to the chassis and tested for overall body height. The posts are removed and shortened slightly and re-tested many times until the body sits at a proper height. Once they are too short. It's a bit late to go back and add material. Once the body sits properly. They are epoxied to the inside of the body.


These two cars were used for this tutorial. Lightweight aluminum chassis's still require weight to be added to corner properly. Either brass, or stick-on lead works great. Note that a relief had to be cut in the Triumph chassis to make room for the crown gear. Some cars have short tires, or tall gears and require a crown gear relief slot. It's simply 3-holes drilled in a row, and then file finished to fit.


Always remember to put safety first when machining anything. Safety glasses are a must when drilling into metal.

Best of luck with your build!!!

Thank you very kindly for looking.