PWD Axle Jig with Tolerance

thingiverse

We run the Camp Snyder woodshop (https://www.gotosnyder.org/rentals/michaels-wood-shop) where we run an annual build program for PWD. We are up to about 500 cars a year and growing. If you have ever witnessd the dramatics when a Tiger cub car blows the axles on race day and seen the panic stricken eyes of the non-handy parent, you are familiar with the issues with the pre-drilled slots. Over 15 years ago, BSA started selling a jig to allow redrilling the axle holes. However, it only does two holes at a time,and being geeks, we had to go one up to allow the scouts to do all four holes easily ( and yes, with adult help for all the Guide to Safe Scouting experts out there). To deal with the inconsistency of the car blocks, we added a threaded insert and screw to the end to lock the car in place, and the holes are big enough to line with metal ferules to prevent wear and tear. (https://www.amazon.com/dp/B07Z95C1TC?ref=ppx_yo2ov_dt_b_product_details&th=1) Please check with your local council because, for reasons we have yet to fathom, some organizations do not allow redrilling of the axle holes.