Model Racing Car

Roy Fang began constructing his remote controlled model racing car in
September 2019. His first step determined whether the model could
be properly assembled. Templates were glued to rigid file folder stock,
then cut out with a utility knife and scissors. Holes were made with
a revolving hole punch. After folding and shaping each piece, the
paper model was fully assembled. Brass fasteners held the pieces
together.

In December Roy began the second step. Templates were glued to
14 gauge (1.63 mm) aluminum sheet metal. Individual pieces were
cut to size on a 36 inch (91 centimetre) Brown Boggs model 321 foot
treadle shear. A 90 degree No. 541 Roper Whitney hand notcher was
used to finish some pieces. Others required aviation snips. Holes were
made with a Roper Whitney No. 5 junior hand punch. Sharp edges were
removed with Shaviv countersink and edge hand deburrers, then
smoothed with 180 grit emery cloth. Final polishing will utilize 400 grit
wet and dry sandpaper. Bends are made with a sheet metal hand
seamer or brake. Curves with a blow horn stake. During assembly
the open-ended aluminum pop rivets will be set with a Marsdon
HP–2 hand riveter.

The model is based upon a 1930s British midget racer that combines
tether car styling with modern RC capabilities. Frank E. Yost produced
the design, found at this link.

1. File folder chassis fully assembled

2. Sheet metal templates on bench top

3. Pieces arranged on sheet metal prior to shearing.

4. Shear with pieces at various stages of completion.

5. Wooden jig