Bonnet & Forming Buck - Hand Tool Method
Plan 5 - Episode 23
In Episode 23 of the Flatbed Felix Pedal Car Build, Ezio builds the bonnet forming buck, and Vaughan explains why it's essential. He then adjusts the radiator backing to fit the new buck and gets to work fabricating the bonnet using only hand tools. This is a great episode for home hobbyists without access to machinery—proof that with the right technique, you can still get the job done with basic tools.
Skills You'll Learn
Ezio builds the bonnet forming buck from plywood and pine, using full-size (1:1) templates to mark each section. He combines several cutting methods—including a drop saw, hand saw, and bandsaw—to accurately shape the straight, angled, and curved components. Clamping holes are added with a hole saw, and digital protractors ensure precise angle setups. Throughout the process, he shares practical woodworking tips like pre-drilling to avoid wood splitting and smart clamping techniques for assembling tricky shapes. The result is a solid forming buck ready for the bonnet fabrication.
Vaughan then uses the new buck to adjust and align the rear radiator panel before moving on to the bonnet. Working from templates, he marks and cuts the metal bonnet, lays out the fold lines for bends and beads, and starts shaping by hand.
To curve the bonnet, Vaughan rolls the metal sheet over a large pipe, gradually forming the curve by repeatedly checking the shape against the forming buck. For the side folds, he clamps a length of steel angle to the workbench and bends the sheet over it by hand. To create the bonnet bead, he uses a timber hammer form that’s been routered to match the bead profile, then hammers in the shallow 3mm swage using a custom corking tool for clean, controlled results.
This episode is a solid example of how much can be achieved with simple tools and a bit of creativity.
Tools You'll Need
Tape measure, square, pencil or marker, centre punch, countersink set, ruler, files, seaming pliers, digital angle gauge, hand saw, power drill and bit set, hole saw set, F- or G-clamps, shaping hammers, dollies, T-dollies, a vice, and a workbench. A circular drop saw and bandsaw are helpful but not essential.
Always wear gloves, safety goggles, hearing protection, and PPE while working.
- Print A3 Manual.pdf
- 17 Plan 5 Bonnet Assembly.pdf
- Wood Router Cut 12mm Marine Plywood 1x B1 DXF.dxf
- Wood Router Cut 12mm Marine Plywood 1x B2 DXF.dxf
- Wood Router Cut 12mm Marine Plywood 1x B3 DXF.dxf
- Wood Router Cut 12mm Marine Plywood 2x B4 DXF.dxf
- Wood Router Cut 12mm Marine Plywood 1x B5 DXF.dxf
- Metal 1mm Lazer Parts Sheet Steel 1x 122 DXF.dxf
- 33 Template 1mm-Thick-Mild-Steel.pdf
- 33 Template 1mm-Thick-Mild-Steel-Sheet.dxf
- A0 18 Template Buck Assembly.pdf
- A0 19 Template Buck Parts.pdf
- A0 21 Template Bonnet-Assembly.pdf
- A0 23 Template Bonnet Parts.pdf
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