OK, at the risk of being compared to a Trekkie, let me give this a shot. I am a cubmaster; one of my boys has moved on out of scouting; and my younger boy is a Webelo I.
As my boys progressed through scouting we did a lot of reseach and had a lot of success. Combined, they have over 30 Pack and District championship trophies. I am often invited to give seminars and workshops and I freely give out every single bit of advice I have. I have also hosted workshops at my house and over 60 boys have built their cars in my shop, and dozens of them have won Pack and District trophies.
There are many ways to build winning cars but here are the keys I stress:
1) your son needs to decide if he wants to build a cool looking car or a fast car. Rarely is a cool looking car fast. Fast cars are generally very basic and boring. Here is an example of a
simple car.
2) note that my son did not use the pre-cut axle slots. It's much better to drill new axle holes as far forward and as far back as possible. Try and find a floor drill press to do that. Don't have the front wheel extend past the front of the car.
3) try and place your weight so that the center of mass is about 3/4th of an inch in front of the rear axle. You can measure that by placing the car on the edge of a ruler to see if it balances there. Another goal is to have 1 ounce of weight on the front wheels and 4 ounces on the back.
4) file and polish axles. An easy way to do this is to put the axle in a dremmel tool or drill and get it spinning. Use a fine file to file off the ridges on the axles. Dont' take off to much material. Less is better than more. Then use wet and dry sandpaper to progressively polish the axle. Start with 600 grit and work your way up to 2500 grit. You can then use a micro polish and to put on the finishing touch. Wash and dry the axle thoroughly after that.
5) BSA changed wheels 2 years ago and the new ones are pretty good. Prior to that the old wheels had a molding bump that had to be shaved off. I wouldn't suggest messing with the new wheels unless you have access to a lathe of some sort. As a side note, don't place wheels on axles and spin them until after you've filed the axles. Otherwise the unpolished axles will make tiny grooves in the bore of the wheels that are nearly impossible to identify and remove. You should verify all wheels spin freely and don't wobble. If they wobble go to the scout store and get new ones.
6) get some high quality graphite from one of the pinewood derby websites. Place the wheel on the axle, squirt graphite in, spin the wheel hard 10 times. Repeat the process 4 times for each wheel. Graphite consists of crytals that must be crushed to be effective. Do not squirt fresh graphite on the wheels unless there is time to break it in.
7) push the axles/wheels into the axle holes. The wheel should be the width of a credit card from the side of the car.
8) roll the ar on a clean, flat surface to make sure it rolls relatively straight. If it moves towards one side or the other more than an inch over a foot you need to make an adjustment. Pull the axle and wheel out of the front hole and try and place a very slight bend in the axle. Do not do that while it is in the car or you will break off some wood. Place the axle/wheel back in and re-roll it. Rotate the axle until it starts rolling straigher.
9) put the car away and do not mess with it again until the race. Most disasters happen during this time.
Here is a thread on building an outlaw car for the
dad's race. Most of the concepts also apply to building a scout class car.