Bosch Soapbox Car

Hello, my name is Inke. Hello, I’m Kai.
Today we are going to build a great soapbox car.
For the kids to play with. Or grown-ups.
We’ve printed out the construction plan for it on the internet. You can download it,
so that you can have a look whenever you want to see if you’re doing everything right.
We’ll manage it.
We’ve had all the components made for us at the DIY store or by a carpenter.
The tools are ready. So let’s get started! We’ll begin with the base tray.
We’ll show you what it will look like later. We’ll screw it all together later on.
But we’ll have to start by making a hole for the control cables.
We’ve sawn one of them out already. Here at the front. We’ve marked the second one,
and now we are going to saw it out. We’re going to drill there to make it easier
to get round the corners with the jigsaw.
And now we’ll saw out the piece with the jigsaw.
Now it’s really easy to get round the corner.
Okay, now I’m going to use sanding paper to make it nice and smooth.
Next we are going to drill the holes for the axles.
And the steering. We’ve already marked them: here, here and
here at the front.
Our base tray is nearly finished. We’ve turned it round and fixed it with screws.
One screw is still missing.
We’ve prepared two strips here and equipped them with a ring nut that the control cables
will be fed through later. The angle at which they are attached is indicated
in the construction plan.
I’m not quite sure that it will fit. No, it doesn’t. Just a minute.
We’ve got a great tool here. Is it that or that?
Give it a try.
I’ll hold it in place.
Bingo. That’ll hold. And now the second side.
Okay, done.
Now we’ll fit the acrylic plates. They’ll make sure that the steering axle
glides better.
There’s something else we’ve forgotten. The lock for the steering axle.
We’ve got all the parts for the axles and the brake rods.
Show us how to assemble an axle like this. This is the rear axle. We’ve already pre-drilled
the holes. The parts have to be placed on top of each
other and screwed together. The same principle applies to the front axle,
but with the difference … … that it is steerable.
Here we have countersunk a carriage bolt using the Forstner drill bit, so that it doesn’t
rub against the axle later.
Here we have the brake rods.
That’s what it looks like when it’s finished. Everything is screwed together.
We have to secure this metal rod somehow. That’s obviously going to be hard if you
just hold it in your hand like that. That’s why we are going to put it in the
brake block here. Until it’s flush.
Now you’ve got a nice drilling jig and you can drill into the metal rod really easily.
It fits! Great tool.
Here at the end, we have cut off a piece of normal garden hose and put it on.
And we used a bit of washing-up liquid to make it easier to put it on.
A little trick. That’s right.
We’ve now screwed the rear axle to the base tray from underneath. The rear axle is rigid.
And here we have the brake rods. We’ve already fitted one of them. And now
I’m going to fit the second one from underneath. We’ve already pre-drilled a hole for this.
First the big washer … … then the little washer.
The first nut… … and the second one, and simply tighten
it.
We’ll do the same with the movable front axle.
The two washers are fitted here.
And tightened with the washers and the nuts from underneath.
Now for the steering wheel. Here it is. We’ve marked it as specified in the construction
plan. We have to drill a hole here, so that we can
saw out these areas with the jigsaw.
Clamp it tight first, so that it doesn’t slip.
And now we drill. One hole is enough.
Okay, now I’m going to use my jigsaw. It’s got a thin curve-cutting blade in it.
Now we’ll cut out the steering wheel. We’ve already marked this here.
First we’ll secure it to the panel.
Now we take this pin and …
… put it in the middle. We’ve adjusted the radius. And now all we
have to do is …
… follow the compass.
Great.
Okay, nearly done. Now we just have to sand down the sides a
bit. By the way, you can also do all this with a router.
The outer curves and the inner curves.
Right, now for the steering unit. We’ve already assembled it as specified
in the construction plan. Now the ... … steering rod …
… goes in the ready-made holes.
Wait, I’ll help you.
It has to sit securely.
Okay, now we take the shaft collars. One from above.
One from below.
And screw them tight.
Now we’ll secure the steering wheel.
Insert the screw and fix it.
It’s tight.
Now we have a car with no steering wheel and no wheels. Here we have the steering wheel
It is fixed on the mark at the right distance...
… with these connecting pieces.
It’s rock steady. Stop! That’s the brake pedal. That’s …
… screwed on down here where the two holes are.
We’ve already fitted the control cables. There are two different circuits: one for
the steering. That’s here. And one for the brake.
That’s back here. To show how exactly this works, it’s best
if we … … turn it over.
Let’s start at the front with the steering. We cut the cable quite generously, so that
it’s not too short. Attach it here to the ring nut and feed it
through here. Then to the steering rod.
Now cross the steel cable. That ensures that the soapbox car turns right when it is steered to the
right and turns left when it is steered to the left.
Onto the other side. Exactly, here it is attached to the ring nut
with a carabiner. And it’s tensioned with this.
With the wire tensioners. That’s right, so that there’s good tension
on it and the steering is easy to move. The second system goes to the brake rods here.
It’s also fastened with the carabiner hook and it’s tensioned using this.
And to ensure that the brake releases and springs back again, we’ve fitted return
springs here.
Two of them. That’s right, on each side.
On the brake pedal there are also ring nuts that the cable is fastened to, just like at
the front on the steering axle.
Now the soapbox nearly looks just like a car,
but there’s something missing.
Yes, we still have to cover the car with the ready-made parts.
The radiator is fitted. Now we’ll carry on at the back.
Great. What now? The side sections!
Okay, now for the second tail. Okay, the second tail is chamfered, right?
Yes, by 25 degrees. With a jigsaw, or circular saw if available.
We’ll mount that here.
It fits.
Okay, what’s left now? Spoiler.
And the last one. Cool!
Anything else missing? Front and rear bumpers and the bonnet.
Then let’s mount the rear bumper first. Okay, perfect.
Are you proud? Yes!
Great. Okay, what else is missing? The wheels.
The wheels, indeed.
Now the front wheel as well.
Now we’ll put the wheel over it. And the second shaft collar to secure it.
But something is missing.
I think I’ve got it.
The seat that we made as specified in the construction guide.
Depending on leg length, you can mount the seat further forward or right at the back
for big kids. To fix it, we have to detach the seat panel
again to screw the seat from the inside out …
… to the tray.
Now the seat panel is put on again and everything is screwed together.
Now the paintwork is finished, too
If you need more legroom, you can redirect the cables situated under the bonnet. To do so,
simply fit ring nuts on the sides and feed the cable down the side.
The soapbox car is finished. Great!