Rear Mud Guard - Hand Forming Method
Plan 4 - Episode 15
In Episode 15 of the Flatbed Felix Pedal Car Build, Vaughan shows how to form the rear sheet metal mudguard using traditional hand tools. This episode is ideal for learning manual shaping techniques, offering plenty of hands-on advice for beginners and hobbyists.
Skills You'll Learn
Vaughan begins by accurately marking and cutting the rear mudguard from a full-scale template using tin snips. He uses a wooden forming buck and a T-dolly in a vice to create the shape, clamping the panel step-by-step to avoid shifting. Various hammers and dollies are used to pre-stretch curves and control buckling.
He folds the edges using nylon mallets and planishing hammers, shrinking the metal into the buck while addressing high and low spots. Final shaping includes roughing, fine-tuning with heavier tools, and dressing with sanding and filing.
Vaughan also demonstrates how to add a swage line by modifying the buck and using a custom dolly and hammer. The episode finishes with welding the ends and final sanding.
In the next episode, Vaughan demonstrates how to streamline the same process using machines like the shrinker and stretcher, making the work faster, easier, and more efficient.
Tools You'll Need
To follow along, you'll need the following tools: a tape measure, square, pencil or marker, utility knife, ruler, file, deburring tool, center punch, power drill, seaming pliers, nylon mallets, soft-face hammer, left and right tin snips, F-clamps, T-dolly, angle grinder, orbital air sander, a vice, welder, and a sturdy workbench.
For your safety, always wear protective gloves, safety goggles, and hearing protection while working to ensure a safe and efficient build environment.
Related Products
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
On Sale
© 2026 Hare & Forbes Pty Ltd. All rights reserved. ABN 96000286957
