Valance, Headlights & Radiator Temp Gauge
Plan 5 - Episode 27
In Episode 27 of the Flatbed Felix Pedal Car Build, Vaughan shows us how to make the valance using hand tools with a wooden hammer form, as well as with machines. Later, he machines a temperature gauge using the lathe and milling machine. These are the final parts before moving on to Plan 6.
Skills You'll Learn
Vaughan works from the valance template plan and starts with the hand tool method. First, he cuts a hammer form out of 17mm formply. He explains how he made the form and shows how the sheet metal valance is clamped in a vice between the wooden hammer forms. With everything secured, he begins hammering the valance into shape.
He breaks down the planishing process into three stages, using different hammers, dollies, and spring hammers. It starts with a nylon hammer for compression shrinking, followed by a medium ball-pein hammer, then a spring hammer to remove waves and puckering. A heavier hammer and dolly are used to smooth out the remaining ripples. Once the final edges are rolled, the hand-forming process is complete. Final adjustments are made using a linisher, and the part is then test-fitted.
Next, Vaughan demonstrates the machine method for making the valance, which is a quicker way to form the fold lines. Using a bead roller, he makes several passes to tip the edge. Since the fold doesn’t reach 90 degrees during this step, he uses a shrinker-stretcher to pull the fold up to the correct angle. Once shaped, he uses hand tools to clean up the surface and remove any blemishes. The final folds are made with a press brake and vice jaws, then the part is trimmed, welded, and attached to the car.
He also walks through the full machine process for making the radiator cap temperature gauge. This part is turned on a bench lathe and finished on a milling machine. He uses a DRO to track measurements and checks progress with a digital vernier. The setup includes a variety of cutting tools—center drills, turning tools, boring bars, parting tools, and a custom radius cutting tool—for precise results. Following the plan, everything comes together cleanly. The process covers the basics of lathe and mill work, including facing, turning, parting off, pilot drilling, and threading.
Once all these parts are completed and fitted, Plan 5 is finished.
Tools You'll Need
You’ll need a tape measure, square, pencil or marker, center punch, ruler, files, vice grips, screwdriver, hex key set, tap and die set, drill and bit set, countersink set, angle grinder, linisher, hand shears, vernier calipers, hammers and dollies, a vice, and a sturdy workbench. A lathe, milling machine, bead roller, and shrinker-stretcher will also be used in this step.
Always wear gloves, safety goggles, hearing protection, and full welding PPE when working.
- Print A3 Manual.pdf
- 17 Plan 5 Bonnet Assembly.pdf
- A3 26 Valance Template.pdf
- 33 Template 1mm-Thick-Mild-Steel.pdf
- 33 Template 1mm-Thick-Mild-Steel-Sheet.dxf
- Metal 1mm Lazer Parts Sheet Steel 1x 129 DXF.dxf
- Wood Router Cut 17mm FormPly Wood 2x HF30 DXF.dxf
- 34 Template 17mm-Thick-Formply Sheet.pdf
- 34 Template 17mm-Thick-Formply Sheet.dxf
- A3 27 Radiator Temperature Gauge.pdf
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