Running Boards & Mud Guard Forming Bucks
Plan 4 - Episode 14
In Episode 14 of the Flatbed Felix Pedal Car Build, Vaughan demonstrates how to fold the left and right running boards, using either traditional hand tools or a faster method with a panbrake. Meanwhile, Ezio constructs the forming bucks for the front and rear mudguards. Whether you're following along step-by-step or just exploring new techniques, this episode offers a solid introduction to aligning wooden assemblies and working with metal. It’s packed with practical tips and hands-on insights for builders of all levels.
Skills You'll Learn
Plan 4 of the pedal car build begins with Vaughan marking out the running boards using precise templates. He shows how to cut the sheet metal using left- and right-hand tin snips. You'll then follow a clear step-by-step folding sequence. Vaughan demonstrates two methods: the traditional “old-school” approach using hand tools, and a more efficient method using a machine called a panbrake (also known as a folder), which speeds up the process and creates crisp, professional fold lines with ease.
Ezio then walks you through the process of manufacturing the front and rear mud guard forming bucks. Starting with accurate measuring and marking techniques, he shows how to transfer details from a full-scale (1:1) template. Using a bandsaw, Ezio quickly cuts out the curved shape, then drills the clamping holes with a hole saw. He demonstrates how to align the four parts, clamp and screw them together, using drilling and countersinking techniques to hide the screw heads. Once the buck is fully assembled, he sands the curve smoothly using both a disc sander and a bobbin sander.
Tools You'll Need
To follow along, you’ll need a tape measure, square, pencil or marker, utility knife, ruler, file, deburring tool, center punch, power drill with a drill bit set, seaming pliers, soft-face hammer, left and right tin snips, a press brake or vice bender, F-clamps, angle grinder, a vice, and a sturdy workbench.
Optional tools that can enhance your workflow include a throatless hand lever shear and a panbrake, which make metalworking faster and more precise. A disc sander and bobbin sander will also help speed up the sanding and shaping of the wooden bucks.
Always wear safety gloves, goggles, and hearing protection while working to ensure a safe and efficient build environment.
- Print A3 Manual.pdf
- 12 Plan 4 Running Boards and Mud Guard Assembly.pdf
- Metal 1mm Lazer Parts Sheet Steel 1x 96 DXF.dxf
- Metal 1mm Lazer Parts Sheet Steel 1x 97 DXF.dxf
- 34 Template 17mm-Thick-Formply Sheet.pdf
- Wood Router Cut 17mm FormPly Wood 4x T19 DXF.dxf
- A0 16 Template Mud Guard Front.pdf
- Wood Router Cut 17mm FormPly Wood 4x T21 DXF.dxf
- A0 13 Template Running Board Left.pdf
- A0 14 Template Running Board Right.pdf
- A0 15 Template Mud Guard Rear.pdf
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