I started with a simple pattern that I altered by putting in a collar.

After I cut the pattern I cut out the various colors of fabric to add the stripes.	Using Iron on paper, I printed out various logos I had gathered from around the net, trying to match the type and size on the origional suit and ironed them on to the costume.	A few I saved until after the costume was made so that I could make sure to center it propery.
The first car I made was paper mache.	Which my son and I painted together	We installed mini flashlights for the headlights. (even though Nascars do not need lights because they don't drive at night!)
We installed break lights too.	Here is a night vision of the headlights	We printed the decals and glued them on and I used fabric straps as a harness.

The next year he wanted the same costume, but the car didn't survive.
So I made him one out of fabric that he still has 6 years later! (and counting)