Both of my boys are in Cub Scouts and have been since they were Tiger Scouts (6 years old). My oldest is bridging into Boy Scouts in March and my youngest is a Bear Scout (8 years old). I’ve done a lot of Pinewood Derbies.
When they both started out, I did all the cutting on my bandsaw but they designed the cars. Now they both use the bandsaw with me looking over their shoulders. That was about the age I learned to use power tools and I still have all my fingers.
I also have a drill press where we polish the axles using a combo of a rasp and fine grit sandpaper. But you have to be sure to get the burr off the head of the nail as well as the shaft.
Our pack rules say that the wheelbase must be the same as the pre cut axle slots, but we can re-drill them. I have the boys re-drill them with a 1/16th drill bit a little forward of the slots. I’ve read that some the slots are not parallel and it allows us to get more weight behind the back wheels. I’ve also taught the boys to drill one front wheel higher than the others, this is supposed to cut down on friction.
We super glue pennies in the car for weight. The boys use the drill press to drill the holes on the bottom before cutting the car and the pennies are cheaper than any other weight system I’ve been able to find.
I’m really surprised that no one has brought physics into the discussion about weight. Physics teaches us that Potential Energy (PE) is mass (m) times gravity (g) times height (h)
PE = m x g x h
So to gain the most PE, you want to maximize the mass and height. So get as close to the 5oz. weight limit as possible and get it as high as possible.
The Conservation of Energy law says all the PE will convert to other forms of energy, such as heat, friction and Kinetic Energy (KE). Doing everything you can to mitigate friction and wind resistance (if you believe wind resistance is an issue - I’ve got no dog in that fight), all you’re left with is KE.
The formula for KE is mass times the velocity squared, or:
KE = m x v^2 (I don’t know how to superscripts)
Simplifying (ignoring friction and/or wind resistance):
PE = KE
mgh = mv^2
gh = v^2
v = sqrt(gh)
Since g is constant, you need to maximize height to maximize velocity.
For those who have never seen a pinewood derby or haven’t seen one in a long time, the wheels of the car straddle a thin but wide piece of wood. That way the inside of the wheels hit the wood to keep it from interfering with other cars in the track. You need to keep the wheels parallel with each other so that the car travels straight down its lane without dragging a wheel along that piece of wood.
When we raise one wheel, it is only by about 1/16th of an inch so it will still grab that piece of wood and keep the car in its own lane should it start to veer.