https://youtu.be/5wmW5UzY6Gg

This started out with a challenge. Design and build a mostly 3d printed car then have a contest to see which is best. Our challenge rules were: cost: $40 not including electronics or filament. you'll notice that I mixed metric and inch parts, that's what I happen to be able to get locally. This is what I came up with.

This car needs 230mm X travel to be printed. I'm including the solid files from 123d design so the chassis file can be modified to print on a 200mm print bed.

Hardware needed:
Radio system with mini metal gear servo for steering
Motor/ESC, I used a 3650 motor combo that sells for $37
Battery: 2200mah 3 cell or smaller
5x225mm shaft for rear axle.
5x10x4 bearings Qty 4 (ID/OD/W)
48P spur gear, I used an Associated 31332 80t part. Take the right rear wheel into a hobby shop and they will hook you up.
Pinion for your motor. Mine is 20 tooth.
100mm 3/16th rod for front axles
3/16x1/2x3/16 bearings Qty 4 for front wheels
1/16 music wire for steering linkage
2 1/16 collars, 2 1/8 collars for steering linkage.
4 1.9" tires, usually sold for crawlers
3 shocks, I used a cheap copy of associated t4.2 shocks 2Front, 1Rear
M3 screws of various sizes. I forgot what all I used.

Printing:
Nothing needs supports except for the chassis, and that only needs it under the front end.
Print with 100% infill, otherwise it's way too light.
I used PLA and it's held up to a good beating so far.

Building: You can probably figure it out. Everything is straightforward with the exception of the rear axle. A groove needs to be filed into the axle shaft right where the cross holes in the wheel hub are located. Run a screw through the wheel hub holes to run through the grooves filed in the shaft. A little tricky but it's pretty sturdy.

The body parts need to be glued together. They come out stronger than I expected.

That's it. Ask if there is anything I missed. Do feel free to tweak, remix, mod, and improve this.