Use a laser cutter to cut the pieces from a 12â€ x 12â€ sheet of 1/8â€ (3mm) wood. I prefer Baltic Birch plywood, buy you can use whatever works in your laser-cutter.
I used 1 x 17 wire nails for the wheel axles, but if you use something different, you may need to edit the size of the holes in the wheels.
Once you have all the pieces, glue the two non-notched pieces together to form the base. These are glued together to get a piece that we can drill holes in to put the nails in. Drilling the hole right between the two pieces works well.
Glue the box pieces together starting with the bottom and the sides. Before you put the top in place you can fill the car with something. My car is named "Poundin' Sand" because I filled it with sand, but you may want to use lead weights, or marbles, or rubber balls. You could also fill your car with candy so that when it breaks open everyone gets a treat. Iâ€™d recommend you name your car â€œThe PiÃ±ataâ€ if you do that!
For the wheels you can either glue 3 of the pieces together to get a 9mm wide wheel, or just put 3 of them on a nail loosely. (You could also choose to use just one or two pieces to make a thinner wheel.)
Derby Car.svg is the original file, and can be edited if needed. If you just want to laser cut the pieces as-is, the DXF or PDF file may work well for you.
If you want to get all fancy, you can add some engraving or cut some holes in the pieces before you cut them.
If you like this car but want to re-adjust everything, you can use any number of box making programs. I like BoxMaker - http://boxmaker.rahulbotics.com/ - but you can also use Box-o-tron - http://www.thingiverse.com/thing:404 - which is right here on Thingiverse.
Once youâ€™re done, you are all ready for the Nerdy Derby!