Wood Base, Bulkhead Assembly & Dash
Plan 3 - Episode 13
In Episode 13 of the Flatbed Felix Pedal Car Build, Vaughan focuses on assembling key structural components including the bulkhead, floor, kickboard, wooden chassis rails, and cross rails. Once the wooden framework is square and secure, he moves on to fabricating the sheet metal dashboard. Whether you're building along step-by-step or simply exploring new techniques, this episode provides a solid introduction to aligning wooden assemblies and working with metal, packed with hands-on advice and practical insights.
Skills You'll Learn
The pedal car truly begins to take shape as Vaughan assembles the wooden chassis rails with the kickboard, floor, and bulkhead. He demonstrates how to properly align and center all the parts, securing them to the correct chassis mounting points using clamps, rulers, and screws for precise positioning.
The final task in Plan 3 is the dashboard. Vaughan walks you through accurate measuring and marking techniques, showing how to transfer information from a full-scale (1:1) dash template. You'll follow a step-by-step folding sequence, using both hand tools and sheet metal machinery—such as a sheet metal folder—to bend the dash into its final shape. Finally, the completed dash is attached using pop rivets before being mounted to the inside of the bulkhead.
Tools You'll Need
To follow along, you’ll need the following tools: tape measure, square, pencil or marker, utility knife, ruler, center punch, screwdriver or power drill, seaming pliers, soft-face hammer, tin snips, press brake vice bender, F-clamps, power drill with a drill bit set, a vice, and a sturdy workbench. Optional tools like a throatless hand lever shear and a panbrake can speed up the metalwork process. Always wear safety gloves, goggles, and hearing protection while working to ensure a safe and efficient build.
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