Building a Pinewood Derby car is a fantastic project for Cub Scouts and their parents. Choosing the right tools is crucial for both safety and achieving a great design. While there are many woodworking tools available commercially, not all are suitable or safe for young scouts. Based on years of experience guiding my son, Stephen, in woodworking projects, including Pinewood Derby cars, I’m sharing our insights on the best tools for cutting a pinewood derby car.
Selecting the Right Cutting Tools for Pinewood Derby Cars
When it comes to shaping your pinewood block into a racing machine, several tools can be used. However, for Cub Scouts, especially those with limited experience, safety and ease of use are paramount. Here’s a breakdown of tools we’ve used, focusing on what works best for younger builders and how to use them safely.
The Scroll Saw: A Safe and Effective Choice
For the major cuts and shaping of the car body, a hobby-sized scroll saw is an excellent choice. Stephen started using the scroll saw at a young age and quickly became proficient. Its up-and-down blade motion is less aggressive than a band saw, making it safer and easier to control for kids. He was even able to cut out the rough shapes for display cars entirely on his own. Many parents are surprised to see how skilled young scouts can become with a scroll saw with proper guidance.
Alt text: A young Cub Scout safely using a scroll saw to cut a pinewood derby car body, highlighting the tool’s suitability for detailed and controlled cuts.
Safety Note: Even with a scroll saw, adult supervision is essential. Always ensure the work piece is firmly supported and that the scout understands safe operating procedures, including keeping fingers away from the blade and wearing safety glasses.
Rasps and Files: Shaping and Refining
Once the basic shape is cut, rasps and files are ideal for refining the car’s body. Stephen started using rasps early on to shape the rough-cut wood. We use rasps with plastic handles for better grip and comfort, and always with gloves for added safety. Some rasps without handles can be risky, so choosing the right type is important. A variety of files in different shapes and coarseness are also useful for smoothing curves and edges.
Alt text: Close-up of hand rasps and files of various shapes and sizes, commonly used for shaping and smoothing pinewood derby car bodies, emphasizing manual control and detail work.
Safety Note: Clamp or use a vise to secure the pinewood block while using rasps and files. This prevents the wood from slipping and ensures better control and safer shaping.
Drill Press with Drum Sander: Smoothing Surfaces
For smoother curves and surfaces, a drum sander chucked into a drill press (operated at a very slow speed) can be very effective. This setup allows for controlled sanding and shaping, especially for concave curves. The slow speed of the drill press is crucial for safety and prevents overheating the wood.
Alt text: A drill press equipped with a drum sander attachment being used to smooth the curved surface of a pinewood derby car, demonstrating a power tool method for efficient sanding.
Safety Note: Always ensure the drum sander is securely attached to the drill press and that the drill press is stable. Adults should set up and supervise the use of the drill press and drum sander at all times.
Router Bit in Drill Press: Creating Weight Pockets
To create a weight pocket on the underside of the car, a router bit in the drill press can be used. By setting a depth limit on the drill press, you can control the pocket depth and prevent cutting through the car body. Marking the area to be removed with a marker helps guide the cut. Clamping the car upside down to a piece of plywood provides stability and control during this operation.
Alt text: Underside view of a pinewood derby car being worked on with a router bit in a drill press to create a weight pocket, highlighting the method for controlled wood removal.
Safety Note: Using a router bit, even in a drill press, requires caution. Always practice on scrap wood first to get a feel for the tool and ensure the setup is safe and effective. Adult operation and supervision are mandatory for this step.
Tools to Avoid or Use with Extreme Caution
While tools like Dremel tools are popular for woodworking, we’ve found them challenging for Pinewood Derby cars, especially for younger scouts. Stephen struggled with control, and their small size can make them slow and frustrating for larger shaping tasks. Similarly, radial arm saws are definitely not recommended for Cub Scouts, and even experienced adults should use them with extreme caution and proper safety measures. These are powerful tools that pose significant safety risks if not handled correctly.
Practice and Patience are Key
Regardless of the tools you choose, practice is essential. We always practice each operation on scrap wood first until Stephen is comfortable with the technique and achieves the desired result. By the time we finish a car, we often have several others in various stages of progress, reflecting the iterative nature of learning and improving skills.
Conclusion: Choosing the Best Tools for Your Pinewood Derby Car Project
Selecting the best tools for cutting a pinewood derby car involves balancing effectiveness, safety, and the skill level of the builder. For Cub Scouts, tools like scroll saws, rasps, files, and a drill press with attachments (used under close adult supervision) offer a safe and effective way to shape their cars and learn woodworking skills. Remember, adult supervision, proper safety precautions, and patient practice are the most important elements for a successful and enjoyable Pinewood Derby car building experience.
