Bulkhead - Part 2 - Firewall, Kickboard & Floor
Plan 3 - Episode 12
In Episode 12 of the Flatbed Felix Pedal Car Build, Ezio focuses on constructing the wooden firewall and shaping the curved top cap for the bulkhead. These components are carefully aligned and securely assembled using wood glue and screws to form the core structure of the front section. With the bulkhead now taking shape, Ezio moves on to cut and prepare the kickboard and floor panel. Whether you’re building along step-by-step or simply exploring new woodworking techniques, this episode is filled with practical insights and hands-on advice.
Skills You'll Learn
Ezio demonstrates accurate measuring and marking techniques using full-scale (1:1) templates, ensuring precise panel layout with the help of cutting guides. He walks through multiple cutting methods, including the use of a track saw, hand saw, jigsaw, and bandsaw, offering a clear look at how to shape plywood and timber components efficiently. You’ll also learn how to drill clean, round holes using a hole saw and power drill. To refine the shapes, Ezio showcases sanding techniques using both a disc sander and a bobbin sander—perfect for forming smooth concave and convex curves. The episode wraps up with a demonstration on assembling the bulkhead using glue and screws, emphasizing alignment, clamping, and durable joinery.
Tools You'll Need
To follow along, gather the following tools: tape measure, square, pencil or marker, utility knife, ruler, center punch, hammer, F-clamps, hand saw, jigsaw, power drill with a drill bit set, hole saw set, track saw, wood vice, and a sturdy workbench. While optional, a disc sander & bobbin sander greatly simplifies the process of shaping curves. For safety, be sure to wear gloves, safety goggles, a dust mask, and hearing protection throughout the build.
- Print A3 Manual.pdf
- 9 Plan 3 Wheels and Wood Base Bulkhead Assembly.pdf
- 32 Template 12mm-Thick-Plywood.pdf
- Wood Router Cut 12mm Marine Plywood 1x 81 DXF.dxf
- Wood Router Cut 12mm Marine Plywood 1x 82 DXF.dxf
- 32 Template 12mm-Thick-Plywood-Sheet.dxf
- A0 19 Template Buck Parts.pdf
- A0 29 Template Doors.pdf
- Wood Router Cut 12mm Marine Plywood 1x B2 DXF.dxf
- Wood Router Cut 12mm Marine Plywood 1x 87 DXF.dxf
- Wood Router Cut 12mm Marine Plywood 1x 89 DXF.dxf
- A0 10 Template Firewall-Bulkhead.pdf
- A0 11 Template Wood Rails Floor Dash.pdf
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