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I have been the head race official for many pinewood derby races. One of the tasks is to manage the check-in process (which really means "do everything you can't find someone else to do"!). As I have helped kids and parents check-in I repeated see the same major mistakes. It doesn't seem to matter whether we have workshops, pass out detailed instructions, or pass out simple instructions, the same mistakes appear each year. These are:

1. Car is significantly under weight - it is very difficult to add 2 or 3 ounces of weight to a car after it is painted and assembled.
Design the car to reach the maximum weight.

2. Car is significantly over weight - it is very difficult to remove more than 1 or 2 tenths of an ounce after the car is painted and assembled.
Weigh the car and adjust the weight prior to final assembly.

3. Car is not lubricated - it is very difficult to effectively lubricate after the car is assembled.
Lubricate the wheels and axles before putting them on the car.

4. Axles are not glued into the slots - regardless of how much care is taken, wheels will become misaligned if the axles are not glued into the slots.
Glue the axles into the slots before the weigh-in, allowing adequate drying time.

5. Weight hangs too far below the car - it is extremely difficult to reduce the clearance after assembly. Design your car to meet the clearance requirement.

Certainly other issues also arise at the weigh-in, but these are the most common. So make the weigh-in a smooth and quick experience by addressing these issues beforehand.

Maximum Velocity
Pinewood Derby Car Plans and Specialty Supplies
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