SunZoon
Lite
User Guide
59022 V0513
Cautionary and Warning Statements
• This kit is designed and intended for educational purposes
only.
• Use only under the direct supervision of an adult who has read
and understood the instructions provided in this user guide.
• Read warnings on packaging and in manual carefully.
• Always exercise caution when using sharp tools.
About the SunZoon Lite
The SunZoon Lite can be easily assembled without alterations, or
the chassis can be shaped and painted for a unique look and to
oer an opportunity to use tools such as a band saw.
Or try experimenting with dierent gear combinations and
wheels. The SunZoon Lite is as basic – or unique – as the builder
wants it to be.
Materials Included
• Basswood chassis board • 2 steel axles
• Gear font • Motor
• 2 large, rear wheels • Solar panel
• 2 small, front wheels • Adhesive tabs, double-sided
• 4 screw eyes • Plastic tubing
Items Needed (not included)
• Ruler
• Scissors
• Hobby knife
• Band saw or sandpaper (optional)
• Paint or other wood nish (optional)
2 SunZoon Light User Guide 59022 V0513
Assembly
1. Deburr the axles by brushing
the ends against sandpaper.
This will make it easier to push
the axles into the wheels.
2. Measure 1" from one of the
ends of the chassis board.
At that measurement, make
a mark on both sides of the
chassis board. Using the ruler,
draw a straight line across the
board that lines up with the
two marks (Figure 1). This is
where the rear axle will go.
3. From the same end, measure
4-1/2" back and make a mark
on both sides of the chassis
board. Again, use the ruler to
draw a straight line across the
board that lines up with the
two marks (Figure 1). This is
where the front axle will go.
4. From both ends of each axle
line, measure 1/4" and make
a mark intersecting with the
axle line (Figure 1). These four
marks will be where the screw
eyes are placed.
5. If you want to shape the chassis
Figure 1
board, do so now. Use a band saw and the template on page
7 to make a tapered body shape. Or cut it to another shape
of your choice, but take care not to cut o the marks for the
axles and screw eyes. Another option is to use sandpaper to
round o the edges of the chassis board.
SunZoon Light User Guide 59022 V0513
6. One at a time, carefully push the screw eyes where the 1/4"
marks cross the axle lines. Taking care to keep them straight,
twist them into the board. Make sure the at side of the
screw eye is perpendicular to the axle lines.
7. If you want to put paint or another nish on the chassis
board, do so now. If you paint the underside of the chassis
(the side with the screw eyes), do not get paint in the screw
eye holes.
8. From the gear font, detach Gear I (40-tooth, 1/8" bore). This
is the drive gear. There may be some burrs – called ashing
– on the gear, which will keep the gear from running
smoothly. With the hobby knife, trim o any ashing.
9. With the scissors, cut four 1/4" pieces of the plastic tubing.
These will be used as spacers on the axles.
10. Start an axle into the hole on one of the rear wheels.
Caution: If it is dicult to push in, you can hold the wheel
and, with the opposite end of the axle against a solid
surface, push down on the wheel to push in the axle. The
axle should not extend past the other side of the wheel.
11. Push the drive gear on the axle end and push it until it is
snug against the wheel. Add a spacer against the gear. Hold
the car so the bottom of the chassis board is facing up and
the back end is toward you. From the left side, push the end
of the axle through the two screw eyes that are on the back
axle line (Figure 2 on the next page). When you ip the car
over, the wheel and gear will be on the right side.
12. Place another spacer on the end of the axle. Push the other
rear wheel on the axle (Figure 2). For the wheels to turn
properly, make sure the wheel and axle parts are not pushed
together too tightly.
4 SunZoon Light User Guide 59022 V0513
13. Place the other axle into
one of the front wheels.
Follow with a spacer
and then push the axle
through the two front
screw eyes. Follow with
another spacer and the
other front wheel (Figure
2). Again, make sure the
parts are not too tight.
If any of the wheels rub
against the chassis, cut
slightly longer spacers
and replace the old
spacers.
14. Flip over the car so the
wheels are on bottom.
Detach Gear G or N
(20-tooth, 2-millimeter
bore) from the gear font.
This is the pinion gear. Cut
o any ashing. Push the
pinion gear onto the motor shaft.
Figure 2
15. One of the motor connection terminals will have a small
dot by it. This is the negative side. Clip the solar panel black
wire to this side. Clip the red wire to the other connection
terminal.
16. Place two adhesive tabs so they line up between the rear
wheels and are centered over the back axle. Peel the paper
backing o the tabs.
SunZoon Light User Guide 59022 V0513
17. Hold the motor so the shaft and gear are facing the same
side as the drive gear. Mesh the two gears together so they
work together but are not pushed together too tightly.
When the motor is positioned so the gears work together,
push the motor onto the adhesive tabs.
18. Place two adhesive tabs on back of the solar panel – one just
under the wires and the other on the opposite end hanging
over the edge just a little. Peel the paper backing o the
adhesive tabs. Press the solar panel onto the body and
motor so the wire end is near the motor and the solar panel
angles toward the front of the chassis (Figure 3).
Figure 3
Your SunZoon Lite is nished! Take it outside on a bright, sunny
day and race it on a smooth, level surface.
Tip: If the motor seems “sticky,” you need to prime it. To do this,
use a nine-volt battery (not included). Unclip the wires from the
motor and hold the two connection points of the battery to the
two motor connection terminals (it doesn’t matter which sides
of the battery touch which sides of the motor). Run the motor in
this manner for no more than ve seconds. Then, reclip the wires
to the motor – the motor should run more smoothly.
6 SunZoon Light User Guide 59022 V0513
Template
To use this template, cut it out
and place it over the basswood
chassis board. Draw a line
around the tapered end to
mark on the board where to
cut. Use a band saw to cut the
shape.
Template
SunZoon Light User Guide 59022 V0513
P.O. Box 1708 • Pittsburg, KS 66762
shop.pitsco.com
Toll-Free Orders 800-835-0686
8 SunZoon Light User Guide 59022 V0513
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