Build Your Own

Solar Car Teach…build…learn…renewable Energy! Page 1 of 1

Background Solar cells are often used in locations where there

isn’t any electricity and where electricity is needed
Not only is the sun a source of heat and light, it’s a in small amounts. In such cases, solar cells are
source of electricity too! Solar cells, also called usually connected to batteries, allowing electricity
photovoltaic cells, are used to convert sunlight to to be stored for use during times when the sun
electricity. Solar cells are used to provide isn’t shining.
electricity all kinds of equipment, from calculators
and watches to roadside emergency phones and A single solar cell is able to produce only a small
recreational vehicles. amount of electricity. But solar cells can be
connected together on a multi-cell panel to
produce larger amounts of electricity. As with
batteries, the more cells that are connected to one
another, the greater the current of electricity that
can be produced.1 Solar panels can produce
enough electricity to power satellites, recreational
vehicles, and equipment for other applications
where electricity is used in large amounts.

Solar panels are becoming common on many homes. For this project, you will be using the electricity
from solar panels to power a small car. Your
Solar cells are most commonly made from silicon, challenge will be to build a solar car that travels as
the same material used to make computer chips.
Silicon is one of the Earth’s most common fast and straight as possible.
elements, and is a major component of sand and
many kinds of rocks. A solar cell is built like a
sandwich, with two layers of silicon separated by a
thin layer of insulating material. All three layers
work together to convert sunlight into electricity.

When sunlight falls onto the solar cell, it produces

a small electric charge. Like a battery, the charge
A completed solar car.
is positive on one side of the cell, and negative on
the other. A wire connects the two sides of the
cell, allowing electricity to flow. This flow, or
current, of electricity can be used to power a small Build It!
light bulb, turn an electric motor, or recharge a These step-by-step instructions provide you with a
battery. plan for making a basic solar car. If you can think
of ways to improve the design of your car, try
them out. Experiment with the materials.

1
Solar cells connected in series (in a long chain, positive to
negative, etc.) will increase the voltage of the panel. Solar
cells connected in parallel (all their positive terminals to one
wire, and all their negative terminals to another wire) will
increase the current, or amperage of the panel. In most large
commercial panels, the individual cells are connected both
ways, with rows of cells in series to raise the voltage of the
panel, and then those rows connected to each other in
parallel, to raise the amperage.
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Substitute parts to try to make the car lighter and

faster. Keep a record of your design improvements Tools and Other Materials
as you go. Gather together the following tools and materials:
• Hot glue gun with glue sticks
Materials
• Scissors
• Retractable utility knife
• Metal ruler
• Pliers
• Roll of clear tape

A. Construct the Body

1. Using the utility knife, cut the foam board
into three pieces — one measuring 20 cm
by 7 cm, and two measuring 2 cm by 7 cm.
Use the metal ruler to guide your cuts.
The tools and materials for making a solar car.
2. Glue the two smaller foam board pieces to
the large foam board piece as shown in the
illustration below.
Order a Solar Car Kit:
3. Using a ruler, carefully mark the positions
SunWind Solar Industries of the screw eyes on the two smaller pieces
1-866-248-5350 (toll-free) as shown in the illustration below.
Web site: http://www.sunwind.ca/

The Solar Car Kit should contain the following

materials:
• 2 solar panels, with contacts
• 2 wooden axles
• 4 screw eyes
• 5 wheels (2 large, 3 small)
• 4 black rubber tires
• 2 elastic bands
• 1 motor shaft pulley
• 1 alligator clip test lead
• 2 cm clear vinyl tubing
• 1 electric hobby motor
• 1 self-adhesive motor clip
• 1 brass paper fastener
• Fine sandpaper
• 1 piece of foam board (24 cm by 7 cm)
Dimensions of the foam board pieces for the body of the
solar car.
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4. Turn the screw eyes into the foam board

pieces. Be sure the screw eyes penetrate
both layers of foam board.

Mount the axles and wheels of the solar car.

4. Assemble the rear axle as shown in the

illustration. Do this by slipping the axle
Turn the screw eyes firmly into the foam board. through the screw eyes, then adding the
spacers followed by the drive pulley (the
5. Slip an axle through the screw eyes to third small wheel) and wheels. You may
check their alignment. The axle should be need to sand the axle a little to allow the
parallel to the end of the foam board. If drive pulley to slide on.
necessary, adjust the screw eyes.

B. Mount the Wheels

1. Slip a rubber tire onto each of the two large
wheels, and two of the small wheels. The
smallest wheel will be used later.

2. With scissors, cut the vinyl tubing into small

sections approximately 5 mm in length.
These will be used as spacers on the car’s
axles (see diagram).
The rear axle with its drive pulley.
3. Test the fit of the wheels and axles. The
wheels should grip the axles firmly. If the 5. Add the front axle with its wheels and
wheels cannot be pressed onto the axles, try spacers, as shown in the illustration.
sanding the ends of the axles to reduce their
thickness slightly, and check again for fit. 6. At this point, check your car to see how
well it rolls. Put the car on the floor and
give it a gentle push. Make sure it rolls
easily and in a fairly straight line. Adjust
the axles slightly to get a better alignment,
if necessary. If the screw eyes seem loose,
carefully place a drop of hot glue where the
screw eyes come through the foam board to
hold them in position.

If necessary, sand the end of the axle to

obtain a good fit with the wheel.
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C. Mount the Motor D. Prepare the Solar Panels

1. Push the small black pulley onto the 1. On the back of each solar panel you
shaft of the motor, as shown on the will find a metal connecting bar and
next page. Slip the motor into its clip. two threaded metal contacts. Each
contact is equipped with a small washer
and a nut. The metal bar and contacts
are used to connect the panels together,
and to connect wires to the panels.
Remove the nuts, washers and metal
bars from the connectors and set these
aside, being careful not to lose them.
2. Connect the two solar panels using one
of the metal connecting bars, as shown
below. Be sure the bar connects the
The electric motor in its mounting clip. . positive terminal on one panel to the
negative terminal on the other. Secure
2. Stretch the elastic band over the rear the connecting bar using washers and
wheel and place it on the axle-mounted nuts, tightening them gently using the
drive pulley. pliers (do not over-tighten).

3. Position the motor so that the elastic

band makes good contact with both
pulleys without being stretched more
than 5 mm. Once you know where the
motor should fit, mark that location on
the foam board with a pencil. Remove
the backing from the self-adhesive
motor clip, and press the clip and motor
onto the foam board in the position that
you marked.
Join the two solar panels using the metal connecting
bar.

3. Strengthen the joint between the panels

by adding a strip of clear tape on both
sides of the panel.

Position the motor on the car body.

Use clear tape to strengthen the joint between

the two panels.
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4. Use scissors to cut the alligator clip test 7. Loop the bared ends of each test lead
lead into two pieces of equal length. over the threaded contact and screw a
Strip about 1 cm of insulation from the nut onto each. Gently tighten each nut
two cut ends, and in each case twist the
exposed copper wires tightly together. using pliers, making sure the wire is
well secured.

E. Mount the Panels

1. Use the utility knife to carefully cut a
small slot in the large foam board
section as shown below.

Strip insulation from the test lead.

5. Using the pliers, carefully bend the

spare connecting bar to form an angled
support for the solar panels, as shown
below.

Cut a slot for the paper fastener.

2. Use the brass paper fastener to secure

the connecting bar to the foam board.
Push the fastener through the hole in
the bent connecting bar, and spread the
tabs where they poke through the slot
in the foam board.
Use pliers to bend the metal connecting bar.

6. Position the second connecting bar on

the threaded metal contact, as shown
below. This will be used to help
support the panels in a later step.

Secure the connecting bar using the

brass paper fastener.

3. Arrange the panel and its support so

that it sits at an angle on the body of
your solar car. Use a small piece of
clear tape to fasten the lower end of the
Connect the wires to the solar panels. panel assembly to the foam board.
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4. Use the alligator clips to connect the Acknowledgements

wires to the terminals on the electric The Pembina Institute acknowledges Michael
motor. If necessary, tape loose wires to Cooke of SunWind Solar Industries, Inc. for the
the body of the car to keep them from design of this car.
touching either the ground or moving
parts of the car. All images courtesy of The Pembina Institute.

Questions
1. Working under a bright light bulb or in
direct sunlight, experiment with the
angle of light hitting the solar panels.
What angle gives you the fastest
rotation of the wheels?

2. How would you modify this car to

Connect the motor to the solar panels. make the wheels turn faster?

3. How would you modify this design to

make a car that could carry or pull a
Test It! heavier load?
Test your car by placing it in bright sunlight,
or under a bright (150 watt or greater) light 4. How could you modify this design so
that your car could run for short
bulb. The wheels should begin to spin quickly. periods in complete darkness or low
If the wheels are turning the wrong direction, light situations?
switch the wires connected to the motor. This
will reverse the direction of the motor. You 5. Sketch a plan for a solar car large
can make small adjustments to the angle of the enough to carry a human. What
panels, the alignment of the wheels, and the technical problems would you have to
overcome to build it?
position of the motor to reduce friction,
increase the power from the panels, and
improve the speed of your car.
Notes:

Test your solar car in full sunlight on a

smooth surface such as sidewalk.