Radiator Shroud / Forming Buck & Grill
Plan 5 - Episode 22
In Episode 22 of the Flatbed Felix Pedal Car Build, Vaughan fabricates the radiator shroud and grill, using a forming buck that Ezio builds. These parts will be fitted later, once the hinged bonnet and side panels are complete. It’s a detailed episode, ideal for both hobbyists and experienced builders.
Skills You'll Learn
Ezio starts by making the radiator forming buck from multiple plywood layers. Using templates, he cuts the profiles, drills clamping holes with a hole saw, and uses a router to round over the front edges—defining the shape of the radiator’s nose.
Vaughan then begins shaping the backing strip of the shroud, which supports the bonnet. Following 1:1 templates, he marks and cuts the metal, then uses both hand tools and machines to shrink and fold the pieces. The templates include gusset guides, which help create clean flange fits once formed over the buck. Clamps hold everything in place during tack welding.
The shroud is further shaped with a shrinker-stretcher and hand tools like a soft-blow and spring hammer. Vaughan progressively works the edges to close the rolled nose section, collapsing the top radius in sections to avoid puckering. A hammer and dolly help smooth everything out.
He then cuts the bottom piece, marks and punches the mounting holes, elongates them where needed, and aligns the parts for welding. After butt welding and cleanup with a T-dolly, the backing strip is plug-welded in place with rust preventative applied between layers.
The grill is cut from a template using throatless shears, then curved over the forming buck using a spring hammer. Vaughan shows how to fit and fine-tune the grill’s placement into the radiator shroud.
Tools You'll Need
You’ll need a tape measure, square, pencil or marker, centre punch, ruler, files, air belt sander, linisher, orbital air sander, power drill and bit set, F-clamps, shaping hammers, dollies, T-dollies, pliers, vice, workbench, and a welder.
Always wear gloves, safety goggles, hearing protection, and full welding PPE while working.
- Print A3 Manual.pdf
- 17 Plan 5 Bonnet Assembly.pdf
- Wood Router Cut 17mm FormPly Wood 2x RB6 DXF.dxf
- 34 Template 17mm-Thick-Formply Sheet.pdf
- Metal 1mm Lazer Parts Sheet Steel 1x 119 DXF.dxf
- Metal 1mm Lazer Parts Sheet Steel 1x 120A DXF.dxf
- Metal 1mm Lazer Parts Sheet Steel 1x 120B DXF.dxf
- Metal Lazer 1.6mm Aluminium Perforated 1x 121 DXF.dxf
- A0 21 Template Bonnet-Assembly.pdf
- A0 22 Template Radiator and Grill.pdf
- A0 23 Template Bonnet Parts.pdf
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