How to Make RC Car Body Shell

Materials

• Lexan or polycarbonate sheet (0.020″ to 0.040″ thick)
• Masking tape
• Scissors
• Hobby knife
• Sandpaper (120-grit and 220-grit)
• Bondo or other body filler
• Primer
• Paint
• Clear coat

Tools

• Heat gun or hair dryer
• Vacuum former (optional)
• Dremel tool (optional)

Instructions

Step 1: Design the Body Shell

The first step is to design the body shell. You can either draw it by hand or use a computer-aided design (CAD) program. If you are using a CAD program, export the design as a DXF or SVG file.

Step 2: Cut Out the Body Shell

Once you have the design, you can cut out the body shell from the Lexan or polycarbonate sheet. Use masking tape to hold the sheet in place while you cut it out. You can use scissors or a hobby knife to cut the sheet.

Step 3: Shape the Body Shell

Once the body shell is cut out, you can shape it using a heat gun or hair dryer. Heat the Lexan or polycarbonate sheet until it becomes pliable. Then, you can bend and shape it into the desired shape.

Step 4: Vacuum Form the Body Shell (Optional)

If you want to create a more complex body shell, you can vacuum form it. To do this, you will need a vacuum former. Vacuum forming is a process in which a sheet of plastic is heated and then sucked over a mold. This creates a three-dimensional shape.

Step 5: Sand the Body Shell

Once the body shell is shaped, you can sand it to smooth out the edges and remove any imperfections. Start with 120-grit sandpaper and then move to 220-grit sandpaper.

Step 6: Fill in the Imperfections

If there are any imperfections in the body shell, you can fill them in with Bondo or other body filler. Apply the body filler to the imperfections and let it dry. Once the body filler is dry, sand it smooth.

Step 7: Prime the Body Shell

Once the body shell is sanded, you can prime it. Primer helps to prepare the surface of the body shell for paint. Apply the primer to the body shell and let it dry.

Step 8: Paint the Body Shell

Once the primer is dry, you can paint the body shell. You can use any type of paint, but automotive paint is a good choice. Apply the paint to the body shell and let it dry.

Step 9: Clear Coat the Body Shell

Once the paint is dry, you can clear coat the body shell. Clear coat helps to protect the paint from scratches and fading. Apply the clear coat to the body shell and let it dry.

Step 10: Mount the Body Shell

Once the body shell is dry, you can mount it to the RC car. Use body clips or screws to secure the body shell to the chassis.

Tips

* Use a sharp hobby knife to cut the Lexan or polycarbonate sheet. A dull knife will tear the sheet.
* Heat the Lexan or polycarbonate sheet slowly and evenly. Overheating the sheet can cause it to warp or bubble.
* If you are using a vacuum former, make sure that the mold is clean and free of debris.
* Sand the body shell lightly. Over-sanding can weaken the sheet.
* Apply the primer and paint in thin coats. Thicker coats can run or sag.
* Let the body shell dry completely before mounting it to the RC car. This will help to prevent the paint from peeling or chipping.

Conclusion

Making an RC car body shell is a fun and rewarding project. With a little time and effort, you can create a custom body shell that will make your RC car stand out from the crowd.