The Badge Archive

Crash Car Build

Fulfills Steps 3, 4, and 5 of GSUSA Brownie Automotive Engineering badge requirements.

Items Needed

  • Egg Options
    • 2.5″ plastic eggs (for testing vehicle safety) & Coins or washers (for adding weight to the egg)
    • Hard boiled eggs (recommended for final test)
    • Fresh eggs (not recommended)
  • 4-1/2″ craft sticks (vehicle frame)
  • 1/2″ craft cubes (support pieces)
  • 1/8″ dowels (axles)
  • Milkshake straws (for axle bushing)
  • Small plastic wheels
  • Hot glue gun with safety nozzle
  • Hot glue sticks
  • 2oz plastic portion cups (optional for structural support)
  • Rubber bands, and/or foam (for securing parts or seatbelt simulation)
  • Cardboard (to protect work surface)
  • Downhill ramp (folding table or inclined surface for testing)

Instructions (Estimated Total Time: 45–50 minutes):

  1. Step 1: Build the Basic Vehicle (10 minutes)
    • Create a frame from craft sticks.
    • Attach axles to the craft stick frame using dowels and small cubes.
    • Slide wheels onto the axles, securing them with clay, rubber bands, or tape.
    • Test basic movement to ensure the vehicle rolls straight and smoothly.
  2. Step 2: Add Safety Features (10 minutes)
    • Create a base for the egg to sit securely in the vehicle.
    • Use 2oz plastic portion cups, rubber bands, and/or foam to secure the egg.
    • Add extra framework or cushioning with cotton balls, sponge pieces, or straws to absorb impact.
  3. Step 3: Test & Record Results (15 minutes)
    • Scouts roll their vehicle down the ramp, letting it crash into a wall.
    • Check if the egg remains safe or cracks upon impact.
    • Record observations about what worked and what needs improvement.
  4. Step 4: Improve & Retest (10 minutes)
    • Make adjustments to reinforce weak spots and better protect the egg.
    • Retest vehicles to compare which designs performed best.
  5. Wrap-Up Discussion (5 minutes)
    • Scouts share test results. They discuss which safety features worked well and brainstorm what they might do differently to improve their design.
    • (Optional) Talk about how engineers design vehicles to protect people in crashes (see discussion points below).

Bonus Challenge: Micro Car

  • Design a crash test vehicle using only 2 full craft sticks and 2 half-sticks.
  • Materials can be used normally, but the frame must stay small.

Engineers design vehicles to keep people safe in crashes.

They use:

  • Crumple Zones – Parts of the car absorb impact to protect passengers.
  • Seat Belts & Airbags – Keep people secure and cushion impact.
  • Strong Frame – Reinforced structures help prevent serious damage.
  • Crash Testing – Engineers test vehicles with dummies to improve safety.
  • New Technology – Automatic braking and sensors help prevent crashes.

Discussion Questions for Scouts

  • What helps protect people in a crash?
  • How did your vehicle absorb impact?
  • What could make your design safer?

References

Tia Kennard