How To Add Custom Louvers To Any Car | Flatbed Felix Pedal Car Build | Plan 5 - Episode 25 |

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Episode 25: Bonnet Side Panels - Custom Louvers

In Episode 25 of the Flatbed Felix Pedal Car Build, Vaughan fabricates the bonnet side louvre panels while Ezio builds the hardwood hammer form. This episode takes a deep dive into a traditional method for forming louvers by hand—one of the most satisfying and hands-on parts of the build so far.

Skills You'll Learn
Vaughan begins by transferring all the critical markings onto the side panels in preparation for forming the louvers. He drills pilot holes and uses an angle grinder with a cut-off disc to plunge through the sheet steel, following a plate steel guide to ensure clean, straight cuts. Once all the slots are complete, he uses the panbrake to make a few simple folds, following the forming instructions laid out on the template.

The hardwood hammer form is a key shaping tool, made by Ezio from a solid piece of timber. Using full-scale (1:1) templates, he marks out the louvre layout, then uses a router to cut the louvre radius and a slot for the guide stop.

To make the process consistent, Vaughan fabricates a simple louvre stop system using square tube and sheet metal. He also attaches a flat steel faceplate to the front of the hammer form, creating a solid edge to fold the metal against during forming.

Each louvre is shaped following a step-by-step sequence based on the plans. Vaughan also creates a set of custom corking and forming tools to get the job done. As the louvers are hammered in, the metal forms cleanly into the slots, resulting in sharp, consistent shapes. He also hints at additional upgrades to the side panels, such as nut inserts, which will be covered in future episodes.

Tools You'll Need
You’ll need a tape measure, square, pencil or marker, centre punch, ruler, files, seaming pliers, vice grips, hacksaw, drill and bit set, countersink set, angle grinder, hand shears, Tin snips, hammers and dollies, panbrake, a vice, and a sturdy workbench. A welder will also be used in upcoming steps.

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