What Are RC Car Bodies Made Of? Polycarbonate, ABS and More
Most RC car bodies are made of polycarbonate (often called Lexan, a brand name): a clear, flexible plastic sheet heated and vacuum-formed over a mould, then painted on the inside so the paint is protected. Scale crawlers and display models often use hard ABS plastic bodies with moulded details, and a few use fibreglass or 3D-printed parts. Polycarbonate flexes and survives crashes; ABS looks more realistic but cracks more easily. Here’s how each is made, painted and repaired.
By Kyle HilsonUpdated: October 20264 min read
Body materials compared
| Material | Made by | Pros | Cons | Found on |
|---|---|---|---|---|
| Polycarbonate (Lexan) | Vacuum forming clear sheet | Flexible, very crash-resistant, light | Less detail; needs inside painting | Bashers, racers, most RTRs |
| ABS (hard body) | Injection moulding | Sharp scale detail, separate parts | Heavier, can crack in crashes | Scale crawlers, Mini-Z, display cars |
| Fibreglass/composite | Moulding | Stiff, paintable outside | Heavy, cracks | Some large-scale and custom bodies |
| 3D-printed (PLA, PETG, TPU) | Printing | Custom shapes | Brittle (PLA), heat-sensitive | Custom and micro cars |
| Die-cast metal | Casting | Very detailed | Heavy | 1/64 conversions (Hot Wheels RC) |
How polycarbonate bodies are made and painted
- Clear polycarbonate sheet is heated and pulled over a mould by vacuum.
- The body is trimmed along the cut lines and the mounting holes are made.
- You wash the inside with warm soapy water (removes mould release), dry it, and mask windows.
- Paint the inside with polycarbonate-specific paint (dark colours first, then lighter backing coats).
- Remove the outer protective film after painting; the paint is protected by the plastic.
Normal model paints don’t stick to polycarbonate and flake off when the body flexes; use paints labelled for polycarbonate/Lexan.
Hard bodies: ABS and scale detail
Hard bodies are moulded like plastic model kits: separate mirrors, handles, light buckets and grilles. They’re common on scale crawlers such as the Tamiya Mercedes G 500 on the CC-02 chassis or ABS-bodied trail trucks. They’re painted on the outside like a model kit and can be weathered for realism. Because they don’t flex, use body mounts with some give and avoid big jumps.
Reinforcing and repairing bodies
- Polycarbonate: reinforce the inside at the nose and post holes with drywall/fibre tape or polycarbonate patches glued with shoe goo-type adhesive.
- Cracks: drill a small hole at the end of a crack to stop it spreading, then patch from inside.
- Post holes: add body washers or grommets so clips don’t tear through.
- ABS: glue cracks with plastic cement or ABS glue from the inside, add a styrene backing strip, sand and repaint.
- Shells for bashing: some makers sell thicker “heavy-duty” polycarbonate bodies.
Which body should you choose?
| You want… | Choose |
|---|---|
| A body that survives crashes and jumps | Polycarbonate, reinforced inside |
| Maximum realism on a crawler or display car | Hard ABS body |
| Light weight for racing | Thin polycarbonate (lightweight versions) |
| A one-off custom look | 3D-printed or fibreglass |
Body care tips
Clean polycarbonate bodies with warm water and mild soap only; solvents can attack the paint on the inside. Store bodies away from heat, as a hot car can warp them. Trim body post holes neatly so clips sit securely, and use body clips with retainers or a clipless mount so the body isn’t lost at speed. Keep a spare body for bashers; a fresh shell is often cheaper than repeated repairs.
FAQ
What are RC car bodies made of?
Mostly polycarbonate (Lexan) for normal cars, ABS plastic for scale hard bodies.
Why are RC bodies painted on the inside?
So the clear plastic protects the paint from scratches; the paint is designed to flex with the body.
Can I paint a Lexan body with normal spray paint?
No, it will flake. Use paint made for polycarbonate.
Is Lexan the same as polycarbonate?
Lexan is a brand name for polycarbonate; in RC the terms are used interchangeably.
More on this topic: the complete RC Cars guide covers the basics behind this article.
About 20 years in RC. Mostly boats in the NAVIGA Mini Eco Expert class, with many self-made parts; also a King Motor Baja 5B, a home-built electric plane, home-built nitro planes he has flown, and an RC helicopter. More about SwellRC
