Head Light Support Bar & Finish Wheel Arches
Plan 5 - Episode 21
In Episode 21 of the Flatbed Felix Pedal Car Build, Vaughan fabricates the headlight support bar and completes the front inner wheel arches. He then welds them to the front mud guards, checks alignment, and makes final adjustments for a clean, precise fit. This episode wraps up one of the most intricate components of the build—shaping and fitting the 3D wheel arches—and is a solid watch for both hobbyists and experienced builders.
Skills You'll Learn
Vaughan begins by shaping the headlight support bar in the vice, bending it to match the design and welding on the tabs that will hold the headlights. He positions and attaches the support bar to the front guards, setting the foundation for the final arch assembly.
Next, he finishes the front wheel arches, demonstrating the last safety fold along the front edge. Before welding the arch to the mud guard, Vaughan applies an anti-rust coating to all the mating surfaces. He shows the full process of butt welding the two components together, followed by a thorough sanding and clean-up to get the piece ready for finishing. He also marks and drills any necessary holes for hardware attachments.
To wrap up the episode, Vaughan makes final tweaks to the front mud guards, adjusting them to allow proper steering clearance and ensure everything lines up the way it should.
Tools You'll Need
To follow this episode, you’ll need a tape measure, hacksaw, square, pencil or marker, centre punch, ruler, files, air belt sander, linisher, an orbital air sander, power drill & drill set, F-clamps, shaping hammers, dollies, pliers, vice, a sturdy workbench and a Welder.
Always wear gloves, goggles, and hearing protection & Welding PPE, to stay safe while you work.
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