Marianne Martinez
Building a pan car can be a complex and time-consuming process, but it can be a rewarding experience for enthusiasts. The first step is to decide on the design and gather the necessary components, which may include a front end, centre shock, rear pod, axle, diff unit, and a plate chassis. Some builders choose to purchase a kit, while others opt for scratch-building, using techniques like 3D printing or laser cutting. The construction process involves assembling the various parts, such as the motor, gears, axles, and steering linkages. Customization is also possible, with adjustments to the rear pod, suspension, and tyre choices. Painting, detailing, and adding decals are the final steps before the car is ready for racing or display.
| Characteristics | Values |
|---|---|
| Main Components | Front end, centre shock, rear pod, axle and diff unit, and a plate chassis |
| Steering Mechanism | Tie rods connecting the servo to the wheels |
| Motor | Attached to a motor mount with a pinion gear meshed with the spur gear on the axle |
| Spur Gear | Central component of the ball differential assembly |
| Chassis Material | Laser-cut acrylic or 3D-printed carbon fiber or acrylic |
| Rear Pod | Adjustable, 3D-printed, with a dual shock absorber setup |
| Tires | Choice matters; use spool and gear for carpet, ball diff for street |
| Suspension | Easier to work with using a damper tube like the Schumacher |
| Belly Pan | Custom-built using a fiberglass mold and carbon fiber |
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What You'll Learn
Choosing the right parts
Compatibility
Ensuring that the parts you choose are compatible with your vehicle is of utmost importance. Incompatible parts can lead to poor performance, safety hazards, and even damage to other systems. Refer to your vehicle's manual or consult a knowledgeable mechanic to determine the exact specifications of the required parts. Pay attention to details such as bolt patterns, load capacity, and sensor compatibility. If you're upgrading, consider whether the part will work with any modifications you've made. For example, larger tires might require adjusted gear ratios or reinforced axles.
Quality and Durability
Inspect the quality of the parts you intend to purchase to avoid buying faulty or worn-out components. Consider the mileage and age of the vehicle the part is sourced from, as older parts may have reduced longevity, while parts from high-mileage vehicles may have experienced more wear and tear. Strike a balance between price and quality, prioritizing longevity over short-term savings.
Reputable Sellers
Choose reliable and reputable sellers when purchasing parts. Established auto part suppliers with a track record of providing quality products are ideal. Online marketplaces, salvage yards, and specialized auto part stores are all potential sources. Verify a supplier's credibility through online forums, enthusiast communities, or customer reviews. Reputable sellers often provide warranties or guarantees, ensuring the quality of the products they sell.
Research and Understanding
Take the time to research and understand the parts you need and how they work with the rest of the car. This knowledge will empower you to make informed decisions and avoid simply following the advice of others without understanding the reasoning behind their recommendations. Learn about the specific requirements of your vehicle, such as power, durability, and unique design considerations. For example, if you're building an off-road vehicle, you'll need a suspension system designed to absorb bumps and dips.
Online Tools and Databases
Utilize online tools and parts databases from trusted automotive retailers to match components to your vehicle's exact make and model. OEM (Original Equipment Manufacturer) parts suppliers often have diagrams and allow you to enter your VIN (Vehicle Identification Number) to verify compatibility before purchasing.
By considering these factors and choosing the right parts, you'll be well on your way to building a reliable and high-performing pan car.
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Chassis design and construction
When designing the chassis, it is essential to determine the type of chassis to use. Two common types are the spaceframe chassis and the monocoque chassis. The spaceframe chassis uses multiple cut and shaped pieces of structural metal tubing, typically steel, joined together to form a strong framework. This design relies on triangulation of the tubes to create a rigid structure. While the spaceframe chassis can be made strong, it often requires more material and weight. On the other hand, the monocoque chassis uses panels of material to structurally complete the box, providing advantages in terms of weight and strength. However, the monocoque design is more complex to build and operate, and any damage to the monocoque structure can be challenging to repair.
The materials used for the chassis construction are also important. Brass, piano wire, and steel tubing are commonly used, each presenting its own set of advantages and challenges. Brass, for example, can be challenging to bend and work with, especially when trying to achieve precise bends. Piano wire chassis are considered easier to make, but ensuring the correct tools and techniques are used is crucial. Steel tubing, as seen in Jaguar's D Type chassis, offers a lightweight and fast construction option, but the design must be carefully considered to ensure safety and performance.
Additionally, when constructing the chassis, it is essential to follow established safety standards and practices. Companies like S&W Race Cars have extensive experience in racing and designing, ensuring their chassis designs meet accepted construction practices. They also focus on creating designs that are easy to maintain, with easily accessible driveline components. Whether building the chassis from scratch or using a kit, adhering to safety standards and seeking guidance from reputable sources is vital.
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Motor and ESC installation
First, remove the necessary screws and tires to access the motor holder. Slide the motor into the motor holder and align it until the screw hole is visible. Secure the motor with the appropriate screws, ensuring that the pinion is aligned with the spur without making direct contact. Reinstall the motor cap and wheel.
Next, determine the placement of your ESC (Electronic Speed Control). The ESC is responsible for regulating the power delivered to the motor and plays a vital role in controlling the speed and performance of your pan car. Refer to your car's manual to identify the optimal location for the ESC. Once decided, secure the ESC in place.
Now, it's time to connect the ESC and motor wires. If you're using a sensorless motor, the wire order and colour matching are not crucial, but for sensor motors, follow the instructions in your manual for the correct wire connections. Typically, the orange, yellow, and blue wires from the ESC connect to the motor wires, and the red and black wires match the battery terminals. However, always refer to your specific instructions to ensure accuracy.
After establishing the wire connections, it's important to calibrate the motor and ESC. This step ensures that they work in harmony and respond accurately to your controls. Follow the instructions provided with your transmitter and receiver to calibrate the system. You may also need to refer to the ESC instructions to set the appropriate jumpers for your battery type (Li or MH) and braking/reverse settings.
Finally, test the setup by connecting the battery to the ESC and ESC to the receiver, and then connect the receiver to the servo. This will complete the circuit, and you can now turn on your pan car to test its performance. Remember to follow the safety guidelines and gradually increase the power to avoid any potential damage from sudden high-speed operation.
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Tyre selection
Tyre Sizing
The size of the tyre is a critical factor. First, check the tyre sizes that are compatible with your vehicle. You can find this information in your vehicle owner's manual or by looking at the sidewall of your current tyres. The sidewall markings indicate the tyre width, aspect ratio, construction, and rim diameter. For example, a tyre marked as "255/55 R17" has a width of 255mm, an aspect ratio of 55 (meaning a smaller sidewall height), and a rim diameter of 17 inches.
Load and Speed Ratings
Consider the load index and speed rating of the tyre. The load index indicates the maximum weight the tyre can safely carry, which is important to ensure your vehicle's load capacity is not exceeded. The speed rating, represented by a letter, indicates the maximum safe speed the tyre can handle. Choosing a tyre with an appropriate speed rating for your vehicle is essential for maintaining performance and safety.
Tyre Performance
Think about the performance characteristics you desire. If you prioritise comfort and a smooth ride, look for tyres that emphasise these features. Touring tyres, for instance, are optimised for comfort. If you seek better handling and steering precision, consider high-performance tyres with higher speed ratings, which provide a stiffer and more precise driving experience. Additionally, if you drive in wet conditions, look for tyres with good wet traction.
Tyre Condition
Ensure your tyres are well-maintained and regularly checked for wear. Shallow treads can lead to unsafe driving conditions, and it is illegal in many places to drive on bald tyres, typically defined as those with a tread depth of less than 1.6mm. Regularly check your tyre pressure and keep it at the level recommended by the manufacturer, as under-inflated tyres can adversely affect handling and fuel efficiency.
Tyre Technology
Tyre technology is constantly evolving, and you may benefit from newer tyre designs. For instance, if you drive an electric or hybrid vehicle, consider HL (High Load) tyres, which are designed to support the weight of such vehicles while maintaining tyre size. Additionally, if you drive in varying weather conditions, all-season tyres or winter tyres can provide better performance and comfort throughout the year.
By carefully considering these tyre selection guidelines, you can ensure your pan car has the right tyres for optimal performance, safety, and comfort.
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Assembly and testing
To assemble and test a pan car, you will need a basic pan car chassis, some blocks of delrin or aluminium, and basic tools such as a file, a fine saw, and a drill.
First, you need to connect the servo to the wheels using tie rods. Then, the motor is attached to a motor mount. The motor pinion gear meshes with the spur gear, which is connected to the axle, turning the wheels. To change the camber, you can drill the axle hole at a 1-degree angle, affecting how the car steers.
You can also make adjustments to the car's setup. For instance, raising the side shock makes the car think the spring is softer, while lowering it makes the car think the spring is stiffer. Adding shims to the right rear adds steering into the turn, while removing them takes steering away. You can also adjust the cross weights to tighten or loosen the car.
Testing should be done incrementally, making one change at a time and noting lap times over a set number of laps. This allows you to understand the impact of each adjustment.
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Frequently asked questions
The main components of a pan car are the front end, centre shock, rear pod, axle and diff unit, and a plate chassis.
First, you need to design the chassis, which can be done using laser cutting. The chassis can be cut from materials such as acrylic or carbon fiber. Next, you assemble the various components, including the motor, axle, and steering linkage. Finally, you can paint and add decals to the car body.
Building a pan car typically requires access to tools such as a jigsaw, table, drill press, and lathe. Additionally, a CNC machine can be useful for cutting and designing certain parts.
Tire choice is an important consideration for pan cars, as different tires are suitable for different surfaces. For example, a spool and gear are used for carpet, while a ball diff is used for the street. To make the suspension easier to work with, a damper tube can be used, such as the Schumacher.
