Thank you all. Sorry to start some chaos on that question. Since I have to use the slot provided and cannot "drill" would I be out of line to deepen the slot to cant/toe the wheels?
Everyone here is competitive. So, sometimes differences of opinion take place ...no need to apologize. Take the advice given, review it and make the best decision that you can and that you are comfortable with.
I looked over your rules quickly and may have missed something, so take this advice after considering all of the rules.
I am not completely sure that you can't drill? It states that "axles holes cannot be drilled into the car". It also states "The axles must be driven into the wooden body's pre-cut axle grooves". Depending on your comfort level ....one could argue that you could drill a pilot hole for the axles into the slot. Keep the pilot hole just small enough so you still need to drive the axles in during install. This would allow you to still use the slots as required and meet the "driven in" requirement. The main reason for this is so that your alignment can be more accurate. It is virtually impossible to install axles accurately without some sort of guide. The pilot hole would act as this guide. Alignment is CRITICAL to having a fast car! Ideally, a jig of some sort would be used to drill these pilot holes.
If you are uncomfortable with that idea, then try a Derby Works axle install tool. While the term "Derby Works" is almost taboo around here, if you MUST, then this tool works decent to install axles into the slots fairly straight. Definitely much better than trying to free hand it. If you go this route, Be sure to clamp this install tool tightly to the body before inserting the axles! Take your time installing the axles. Use some extra/junk axles for this ...push//drive them in a bit and stop ....let the wood relax .....wait a minute or so ....push/drive them in a little further and stop ....wait and repeat. I would do this in 4-5 increments for each axle. Remove the axles with an axle pliers. Reinstall them and leave overnight. This helps to relax the wood. I would leave the Derby Works install tool clamped in place overnight while letting the wood relax. The next night, move the tool to the other slot and repeat for those axles as needed.
Your rules say you must use the axle slots in the body, so that means your are stuck with the 4 3/8" axle centers. I did not see where it mentioned that the axles slots needed to remain in the original locations. So, another important item would be to cut one end off your block so that one slot (the rear of the car) is 5/8" from the end. Then glue the end you removed to the front of the car. You will loose a saw kerf in doing so, but your rear axle placement will now work to your advantage. When the weight is placed in the rear of the car ( approx 2 ounces behind the rear axle) it falls further/longer down the hill. This gives you a stronger push and a better conversion of your potential energy. The loss of a 1/8" saw kerf will be more than offset by the new rear axle location. Read about weight placement and the advantages of having both the weight and rear axles in this location.
Axles and wheel/bore prep are and will be also key to having a fast car. Read as much as you can about this and get some decent products for your bore prep. It will pay dividends. It pays to buy extra wheels and axles from your scout shop so you can sort thru them to get the best wheels and axles for use. It also gives you extra wheels/axles to practice on along with extra axles for other uses.
Anyway those are just a few ideas that you may or may not use based on both your skill and comfort level. Remember to have FUN and spend quality time with your cub. This can be a really great way to teach both physics and some very important life lessons. Don't waste this opportunity to teach your Cub these things!
Do your best! Good luck!
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