A gas-powered car with a wooden frame. I designed the whole thing in Onshape — frame, parts list, drivetrain layout — then organized a team of five to build it in a garage and on a driveway. It started as a CAD model and ended up on the road.
What I was responsible for
I independently developed the CAD design: the wooden frame, the seat and steering column, the rear module that carries the engine and axle, and the parts list that came out of it. Once the design was ready, I coordinated a five-person team to build it.
- Full CAD model and parts/BOM in Onshape
- Wooden frame design
- Braking system and throttle integration
- Coordinating construction across a five-person team
Problems we had to solve
Most of the real engineering happened when the parts showed up and didn't quite match the plan.
- Engine performance and stalling issues
- Finding a chain that was compatible with our sprockets — and actually in stock
- Routing and integrating the throttle cable
- Brake caliper compatibility and how to mount it to a wooden frame
- Translating the CAD model into a structure that held together physically
From CAD to the road
How the build progressed, stage by stage. Select any photo to view it larger.
- Stage 1 of 6
Concept and CAD
The car started in Onshape. I modeled the frame, seat, steering column and tie rods, and the rear module carrying the engine and axle.
Full assembly in Onshape Side view
Top view — steering linkage and rear axle
Front view — tie rods
Rear engine module
Front frame and seat
- Stage 2 of 6
Planning and component selection
From the model came the parts list: lumber cut sizes, the Predator 212cc engine, the chain drive and the brake hardware. The cut lumber was laid out against the plan before assembly.
Lumber cut and laid out against the plan Cutting frame pieces
- Stage 3 of 6
Frame fabrication
The floor pan and frame went together on the driveway and in the garage.
Fastening the floor frame Framing on the driveway
Late-night work on the floor pan
Moving the build into the garage
Drilling the floor pan
- Stage 4 of 6
Mechanical assembly
The rear module was built as its own frame, then the axle, wheels, steering column and tie rods went on.
Rear frame dry fit Rear axle and sprocket installed
Steering column and front end
- Stage 5 of 6
Engine and drivetrain
The Predator 212cc engine was mounted on the rear module and connected to the axle by chain. The brake caliper had to be adapted to mount on wood.
Engine mounted on the rear module Brake caliper, disc and sprocket on the rear axle
- Stage 6 of 6
Testing and driving
After working through stalling, chain and throttle issues, the car ran — and we drove it.
Driving the finished car