Chassis - Part 2
Plan 1 - Episode 2
In Part 2 of the Flatbed Felix Pedal Car Build, Vaughan fabricates and fits the remaining chassis components, including the rear cross member, rear axle support, front gussets, side running board supports, side brackets, crank base plate, steering column support, and steering arm pivots. The episode wraps up with precise MIG welding to assemble the full chassis and the installation of nut inserts, preparing the frame for future bolt-on components.
Skills You'll Learn
This episode dives into more advanced metalworking techniques. You’ll gain experience with cutting angles (including 45° cuts), accurate measuring, drilling, deburring, and assembling a chassis squarely using MIG welding. Vaughan also demonstrates how to bend and shape a steering support using a vice, press brake, and sheet metal folder—all while working from detailed plans and templates.
Tools You'll Need
To follow along, you’ll need: a tape measure, square, scriber or marker, clamps, angle grinder, drill, metal files or deburring tools, MIG welder, workbench, vice, tin snips or shears, sheet metal folder, hammers, and general hand tools. Be sure to wear appropriate personal protective equipment, including gloves, safety goggles, and hearing protection.
- Print A3 Manual.pdf
- 1 Plan 1 Chassis Assembly.pdf
- Metal 1.6mm Lazer Parts Sheet Steel 2x 12 DXF.dxf
- Metal 1.6mm Lazer Parts Sheet Steel 4x 11 DXF.dxf
- Metal 1.6mm Lazer Parts Sheet Steel 8x 10 DXF.dxf
- Metal 1mm Lazer Parts Sheet Steel 1x 14 DXF.dxf
- 33 Template 1mm-Thick-Mild-Steel-Sheet.dxf
- Metal 5mm Lazer Parts Sheet Steel 1x 13 DXF.dxf
- 33 Template 1mm-Thick-Mild-Steel.pdf
- A0 2 Template Chassis-Parts.pdf
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