Fitting the Bonnet, Side Panels & Radiator
Plan 5 - Episode 26
In Episode 26 of the Flatbed Felix Pedal Car Build, Vaughan shows us how to align and fit all the bonnet panels to the front of the pedal car. Just like the side panels and radiator, the bonnet needs to be square and flush. Vaughan also demonstrates three different ways to attach the piano hinge—plug welding, pop rivets, and spot welding. The car is really starting to take shape, and with these components in place, it’s nearly ready for show time.
Skills You'll Learn
Vaughan walks through all the steps for measuring and checking that everything is square before fitting the front end panels. Final adjustments are made to the inner guard before moving on to the radiator installation. The side panels are secured using wood screws, metal tack screws, and vice grips—making sure each panel is square, flush, and level.
With the side panels in place, the next step is attaching the hinge components to both the firewall and the radiator.
Vaughan carefully fits each half of the bonnet and clamps it in place with vice grips. He demonstrates key techniques to ensure the bonnet sits perfectly, using the vice grips to fine-tune alignment. He then marks the final center edge to be guillotined, ensuring the left and right sides are symmetrical.
Next, he demonstrates three methods for attaching the bonnet to the hinge: plug welding, pop riveting, and spot welding. All three are effective—it just comes down to your preferred look. Vaughan explains each process step by step, offering useful tips like using weld-through primer to improve the welds.
With the bonnet mounted, Vaughan shows how to fix any spring-back using a hammer and spring hammer. In the next episode, the focus shifts to fabricating the valance.
Tools You'll Need
You’ll need a tape measure, square, pencil or marker, centre punch, ruler, files, vice grips, screwdriver, hex key set, drill and bit set, countersink set, angle grinder, hand shears, hammers and dollies, a vice, and a sturdy workbench. A welder or spot welder will also be used in upcoming steps.
Always wear gloves, safety goggles, hearing protection, and full welding PPE while working.
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