Forming & Mounting The Rear Guard | Flatbed Felix Pedal Car Build | Plan 4 Ep. 17 |

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Episode 17: Rear Mud Guards & Running Boards Fitment + Front Mud Guard - Hand Forming Method

In Episode 17 of the Flatbed Felix Pedal Car Build, Vaughan fabricates the rear guard mounting brackets, assembles and fits the running boards to the chassis cross members, and mounts the rear guards to the pedal car’s wooden chassis rails using the new brackets. This episode focuses on proper alignment and fitment techniques, making it a useful guide for home builders and hobbyists following along.

Vaughan also begins shaping the front mud guard using a wooden forming buck and traditional hand-forming methods. He demonstrates a range of metal shaping skills, finishing the guard by fabricating and welding on a custom nose piece.

Skills You'll Learn
Vaughan starts by shaping the sheet metal for the rear guard brackets, forming the curve over a T-dolly while accounting for springback. He also shows how to create the same shape using curving rolls. Once the curve is set, he bends the ends using vice press brake jaws, then deburrs and linishes the parts for a clean finish.

He then fits and aligns the running boards with vice grips before securing them with metal screws. Precise measuring and alignment are key when it comes to the rear guards. Vaughan uses timber blocks to prop them in place and a flat bar to clamp everything straight before fastening them with an air drill.

For the front guard, he transfers the template onto sheet metal and trims the excess with tin snips. The nose piece is shaped by hand over a tapered dolly clamped in a vice, using a hammer to get the form just right. Once it's shaped, he welds it to the main panel and finishes it with sanding and further shaping using hammers and dollies. If you’re just getting started on the front guard, check out the previous episode for the initial steps.

Tools You'll Need
To follow along, you’ll need a tape measure, square, pencil or marker, utility knife, ruler, file, deburring tool, seaming pliers, nylon mallets, soft-face hammer, left and right tin snips, F-clamps, T-dollies, angle grinder, orbital air sander, a vice, a sturdy workbench, and a welder.

Always wear protective gloves, safety goggles, hearing protection, and full welding PPE while working.

Track ID: 1222187
Monetization ID: KJKOO8MMGXHALEU2