Wheel Arches - Machinery Method
Plan 5 - Episode 20
In Episode 20 of the Flatbed Felix Pedal Car Build, Vaughan continues Plan 5 by shaping the front inner guards using machinery methods. This episode is a must-watch for hobbyists and advanced builders alike, as it dives into one of the most intricate parts of the project—the 3D wheel arches.
Skills You'll Learn
Vaughan uses 1:1 paper templates and TIG wire guides to establish the correct curves and profile. He demonstrates key techniques like shrinking, stretching, and using a bead roller to follow a planned sequence. He also planishes the surface to smooth out inconsistencies and uses dollies to refine the overall shape to match the desired radius.
After rough shaping, Vaughan test-fits the arch to the front guard to check alignment and flow. He continues adjusting the edges with the help of the forming buck, combining stretching and shrinking to fine-tune the shape. He uses a trimmed paper template over the buck for precise fitting, then flattens the edges using a corking tool while explaining the function of custom dollies.
Folds 3 through 5 are created using pressbrake vice jaws to produce clean, consistent edges. Step 6 is completed on a tapered T-dolly and shaped by hand. Once the arch is nearly final, Vaughan test-fits it to the running board using vice grips and secures it temporarily with tack screws, explaining the alignment process along the way.
Tools You'll Need
To follow this episode, you’ll need a tape measure, square, pencil or marker, utility knife, ruler, file, deburring tool, seaming pliers, nylon mallets, soft-face hammer, tin snips (left and right), F-clamps, shaping hammers, dollies, pliers, an orbital air sander, a vice, and a sturdy workbench.
Always wear gloves, goggles, and hearing protection to stay safe while you work.
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