Bonnet - Machinery Method
Plan 5 - Episode 24
In Episode 24 of the Flatbed Felix Pedal Car Build, Vaughan fabricates the bonnet using the machinery method, then moves on to fitting the hinge and joining it to the back of the radiator. He uses a variety of sheet metal machines while constantly referring to the forming buck to check the shape. This is a great episode for anyone who owns—or wants to learn how to use—tools like an English wheel, bead roller, and panbrake.
Skills You'll Learn
Vaughan starts by rolling a curve into the bonnet using sheet metal rolls. He carefully checks the profile against the forming buck to ensure symmetry across both sides. This is a solid demonstration of roll forming—showing how to follow guide lines, apply consistent pressure, and avoid over-bending.
With the curve roughed in, he moves to the English wheel to refine the transitions between radii. Using three different radius dies, he blends out the shape, smoothing the surface into a uniform, flowing bonnet curve.
Next, Vaughan uses a sheet metal panbrake to reverse and flatten the side panels. After transferring the fold lines to the inside face, he carefully folds both side edges of the bonnet, producing clean, crisp bends that align perfectly with the forming buck.
He then switches to a motorised bead roller to swage the sides of the bonnet. Vaughan walks through the step-by-step process and explains how to use 3/8" swaging dies to get a clean, accurate result.
After that, the bonnet is cut down the center with hand shears, and each half is folded along the inner edge using the panbrake. Vaughan cuts the piano hinge to length and fabricates the hinge supports, showing a clever way to get the hinge to function smoothly and align with the radiator shroud. He screws the hinge bracket into the rear of the radiator and mounts it to the buck to check fitment. The actual bonnet-to-hinge welding will be completed in the next episode.
Tools You'll Need
You’ll need a tape measure, square, pencil or marker, centre punch, ruler, files, seaming pliers, vice grips, digital angle gauge, hacksaw, drill and bit set, countersink set, angle grinder, hand shears, sheet metal rolls, English wheel, panbrake, motorised bead roller, a vice, and a sturdy workbench. A welder will also be used in upcoming steps.
Always wear gloves, safety goggles, hearing protection, and full welding PPE while working.
- Print A3 Manual.pdf
- 17 Plan 5 Bonnet Assembly.pdf
- A0 18 Template Buck Assembly.pdf
- A0 19 Template Buck Parts.pdf
- A0 21 Template Bonnet-Assembly.pdf
- A0 23 Template Bonnet Parts.pdf
- 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
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