Mounting Headlights on a Pedal Car

[@Blondihacks]

I learned so much from this one! The triangle bending problem was a real revelation for me. I have had that exact problem, but the solution of bending a rectangle first never occurred to me. Wonderful stuff!

[@RonCovell]

Thanks so much, Quinn. Yeah, when you're bending expensive materials like copper and brass, you don't want to scrap any parts!

[@ianloughney9570]

Ron Covell: Your favorite youtuber's favorite youtuber

[@msmith2961]

Going the extra mile and demonstrating the bend with poor leverage rather than saying 'don't do this' is excellent teaching technique. Looking forward to your next video!

[@RonCovell]

I'm so glad you liked the video - more on the way!

[@vbertrand]

I know I say it everytime, but I mean it : you, Sir, are a National Treasure! Thanks for sharing.

[@RonCovell]

Wow, thank you!

[@Watchyn_Yarwood]

Absolutely!

[@davidwalters4014]

Mr. Covell, you remind me of Bob Ross; but in metal! Thank you for sharing these tips, tricks and years of experience!

[@RonCovell]

Wow, thanks!

[@SteveBrecht]

Thanks Ron, as always you break down tasks like this into several steps that seem obvious after seeing them, but seem like magic beforehand. Learned a lot again!

[@RonCovell]

Fantastic!

[@6061]

Great thinking on the angled, threaded hold down on the top. That'll make it nice and sturdy. 10/10 as always

[@RonCovell]

Thanks so much, Aaron. Getting comments from someone as skilled as you means a lot to me.

[@peppedpd]

I like it how you explain all the steps while doing them. And your clear and slow talk helps me as an old Swede with poor english to easy understand.

[@RonCovell]

I'm so glad you like my videos! I have over 100 on KZbin, so there may be more that you would like.

[@manuellongo4365]

As always, a pleasure to watch (and learn). Bending a rectangle first is such a simple and elegant idea that never occurred to me.

[@RonCovell]

Thank you! Cheers!

[@jerekirkpatrick2092]

Ron, using a standoff at the rear was a great idea, insuring proper fit at final assembly.

[@RonCovell]

Thanks, Jere. I thought about making new tabs and slots at the rear, but in the end the standoff turned out to be a better solution. I had to run this idea by the owner of the pedal car, since I added a 'not-stock' hole. Thankfully, he was OK with that.

[@TimWheelus]

Ron, Thank You for helping me with this project. I definitely learned a lot from our visit and your video.

[@RonCovell]

Tim - Glad to help!

[@Mr_Mooo]

Watching you reminds me of my sheetmetal teacher in high school. He also had great attention to detail and enjoyed working through a problem. Watching you work and resolve issues is a delight.

[@RonCovell]

I'm delighted that you enjoy my videos, and also that you had a great shop teacher!

[@spinyuk]

Another fascinating and detailed video,. As ever, you make it all look so easy, but I know the next time i'm trying to make a repair panel fit neatly to my '78 VW bus, I'll be reminded how not easy it is :D

[@RonCovell]

The more you do, the easier it gets!

[@seeburg]

Even on this small part, your attention to detail shines through. You are a true master of metalwork and a joy to watch.

[@RonCovell]

Thank you VERY much!

[@russtuff]

I've fallen into that trap before, trimming before bending. This has been an excellent demonstration.

[@RonCovell]

Thanks!

[@SteveBrecht]

Hey Ron, there is a talented body man with a channel called: Carter Auto Restyling. Amazes me what he can do with metal and he uses a lot of classic techniques. Whiz with a hammer and dolly. I thought you might enjoy some of his content. He pretends to be an idiot with a lot of tongue in cheek humour, then pulls off some of the best metal work I've seen (but I'm no expert). He's referenced admiring some of your work from magazines as well. Looking forward to your next video!

[@RonCovell]

Thank you for letting me know about the Carter Auto Restyling channel. I watched a couple of his videos, and he is a very talented man, with an unusual (but very good) style of communicating.

[@VladekR]

But, there is only one King

[@tomthompson7400]

Thats a masterclass on simple bending , perfect.

[@RonCovell]

Well, bending can be quite simple if you use the right techniques!

[@tomthompson7400]

@@RonCovell it can also be a pita if you dont know the right techniques , and that was a total masterclass in basic bending and bench fitting , so so great of you to share your knowledge.

[@floridian7143]

Great video! You cease to amaze me! I took your class in the early 90's in New Paltz NY Thanks for sharing, always interesting!

[@RonCovell]

I'm so glad you liked this one!

[@sjoemie_himself]

Thank you for sharing your knowledge with us again Ron. The trick with bending the part as a square instead of an almost finished part I genius. Thinking outside the box. Very neat small project with interesting techniques! Greetings from the Netherlands, Mark

[@RonCovell]

Thank you so much, Mark!

[@JockeSelin]

It’s magical to watch you do your craft! 🙂👍🏻

[@RonCovell]

Thank you so much 😀

[@cest7343]

A pleasure to watch and a masterful execution Master Covell. We have become accustomed by You to a high standard 👍

[@RonCovell]

Thanks!

[@joewolf4483]

Your videos are well made and thought out ... the content is always interesting and I learn every time I watch one ... keep them comming ...

[@RonCovell]

Thanks, and there are more videos on the way!

[@paulnagel8161]

A master of their craft makes everything look easy. Another brilliant video!

[@RonCovell]

I appreciate that - truly!

[@RR-mt2wp]

So great seeing you uploading a new video Ron. All the very best to you. I'll greatly enjoy seeing it.

[@RonCovell]

Thanks so much!

[@jasongarland3165]

Mr. Lovell is the Bob Ross of sheetmetal work

[@RonCovell]

Thanks so much!

[@jasongarland3165]

@@RonCovell thank you for taking time to share your years of experience!

[@wookieecantina]

Ron, you're truly such an iconic craftsman and I'm so thankful for all of your videos. Thank you for creating and sharing your many wonderful techniques and methodologies.

[@RonCovell]

You are very welcome

[@jimintaos]

Man-o-man- This was exactly the video I needed and it just dropped into my feed without my doing any kind of search. I'm building a travel trailer and wanted to make a sort of retro looking taillight housing. I am just now finishing up the fenders and running boards and the next task is to start working on the exterior electrics-perfect timing. Thank you.

[@RonCovell]

Hey, I'm glad you found the right video at the right time!

[@nat7278]

Absolutely inspiring! I love seeing you walk us through how and why you do each step.

[@RonCovell]

I'm so glad!

[@outsidescrewball]

Enjoyed….thank you for sharing your craftsmanship and mentoring ❤

[@RonCovell]

Thanks for watching!

[@jc5c515]

Turned out beautiful! A simple project but loaded with smart tips

[@RonCovell]

Glad you liked it!

[@grantcurtis1521]

Always amazing to watch you work. Amazing craftsman and artist

[@RonCovell]

Thank you so much 😀

[@dionbetts6689]

Wow! Just discovered your channel, I’ve got some catching up to do! Amazing work!

[@RonCovell]

I'm so glad you found my channel! I have over 100 videos, and there is a very good chance you will like some of the other ones.

[@ODGColornChrome]

Awesome tricks of the trade! Your knowledge and skills are beyond compare Ron!

[@RonCovell]

I appreciate that!

[@JustinPaul1st]

Got in abit late had to catch up...thank you for the tips on making conical shapes...you make it seem so easy...Guess thats why you the Master

[@RonCovell]

Well, I've had about 55 years of practice, so I've learned a few things!

[@johnmolnar2957]

Enjoyed the video . thanks for sharing & for the tips . you're a wealth of information . I have to remember that bending the rectangle trick !

[@RonCovell]

Thanks so much!

[@joell439]

Thanks Ron for another fabulous tutorial. So nice to see your doing well. 👍😎👍

[@RonCovell]

Thanks 👍

[@adambergendorff2702]

Really liked the slip fit of the bezel, nice trick!

[@RonCovell]

Glad you liked it!

[@RR-mt2wp]

It's wonderful to watch the skills you show, Ron.

[@RonCovell]

Thanks a million!

[@markd6777]

Great job Ron, as always.

[@RonCovell]

Thanks a million!

[@darrellbauer2464]

Another great video with great solutions Ron.

[@paulthomas-lo3ry]

Thaks for the video Ron. Learning from you throughout the whole thing. Great informative information. Thanks

[@RonCovell]

Glad to hear it!

[@manythingslefttobuild]

Great video Ron, thank you for sharing.

[@RonCovell]

Glad you enjoyed it!

[@dougwernham5209]

Very interesting & helpful video thanks Ron.

[@RonCovell]

Glad you enjoyed it!

[@hamdiklcarslan4435]

Great work Mr Covell, thanks for all the information.

[@RonCovell]

You are more than welcome!

[@johnfields7936]

Another excellent tutorial Sir, thank you very much!

[@RonCovell]

Glad you liked it!

[@TheDistur]

Nice work Ron!

[@RonCovell]

Thank you! Cheers!

[@rgreen93021]

YEA! Another Master Class from the Metal Genius. Thank You.Ron!

[@RonCovell]

I'm so glad you liked it!

[@johnhughes8563]

Excellent video, very interesting. Thank you so much.

[@RonCovell]

Thank you too

[@dominosgarage]

Loved this video. I learned SO much

[@RonCovell]

Thanks for letting us know!

[@dominosgarage]

​@RonCovell what brand of metal shears do you use?

[@RonCovell]

I favor the Wiss brand, but they are certainly not the only good ones. Many American metalworkers like the Midwest and Malco brands, and the Klenk and Gilbow brands have many fans in Europe. I'm just listing the ones I'm most familiar with, and there are many others. I made a video on using snips properly, which you might enjoy: kzbin.info/www/bejne/rmmzdYV3qLJ3jsU

[@dominosgarage]

@@RonCovell I have been using one's from the box store hardware companies, Home Depot, Lowe's, etc.. They suck. Lol

[@kyrathorsinclaire]

Absolutely wonderful work.

[@RonCovell]

Many thanks!

[@RubyCustom]

Killer fab ,love your vids keep them coming

[@RonCovell]

Thanks so much! More videos on the way.

[@jamesvincent5142]

Thanks Ron! It's always the little things that make the switch turn on for big picture.

[@RonCovell]

Glad to hear that!

[@TheIronHeadRat]

Amazing work, thanks for sharing 👍

[@RonCovell]

Glad you enjoyed the video!

[@cpcoark]

Your work s A1, bar none. I wish I had someone like you around in the 60's to expose me to the possibilities of sheet metal work. I loved working with it in HS, but sadly, that was ware it ended.

[@RonCovell]

Well, you could always pick it up again anytime you like.

[@losjugetesdesara9566]

muchas gracias por las clases maestro DIOS le bendiga

[@RonCovell]

Estoy muy contento de que hayas disfrutado el video!

[@warrenholmar1129]

Thanks for the video, Ron.

[@RonCovell]

You bet!

[@yaasikasa17]

Love your work!

[@RonCovell]

Thank you!

[@ptonpc]

Just missed the live video. Hope everyone is having a good weekend!

[@RonCovell]

Things are great so far. I had about 100 viewers on the Premiere, and several of us had a lively chat.

[@ddblairco]

very nice, thank you

[@RonCovell]

Thank you too!

[@CraigHollabaugh]

I picked up several tips here, best one was rolling the rectangle then cutting. I would have been hammering on a dolly to form. Hey, I'm making a garden kaleidoscope and that lens&bezel might work well for it. Where did you buy it? Thanks putting this together. Technique, camera work, lighting, audio, script and editing, all exceptional.

[@RonCovell]

I will check with the person I did the job for - who supplied the lens and bezel. If you send me an email at: [e-mail] I will let you know what I find out. I did find a source for brass bezels in different sizes here: parawire.com/craft-store/round-rolled-edge-brass-bezel/

[@CraigHollabaugh]

@@RonCovell Thanks Ron, sent you email.

[@maxthomson2096]

As usual Ron ,, amazing work, would it be possible to see a shop tour of your workshop? thanks...

[@RonCovell]

That's been on my 'to-do' list for some time. Thanks for the gentle reminder!

[@maxthomson2096]

@@RonCovell all the best mate and thanks,,

[@markgordon4368]

Great stuff very informative 😊

[@RonCovell]

Glad you enjoyed it!

[@markgordon4368]

@@RonCovell it's the order of play that I find most interesting and the small things that set time served against academia.

[@RonCovell]

Good to hear!

[@adrianwilliams763]

Awesome job.

[@RonCovell]

Thank you! Cheers!

[@AlexAndOlmsted]

Great video! Thanks so much for sharing your knowledge and process. One question I have: Would the original lens cover have been a slip fit like you did? I would think the vibration of riding the pedal car would put it at risk of coming loose.

[@RonCovell]

Honestly, I don't know how the original bezel was held in place. I'm sure they devised a system that was more secure than mine, since the kids who drove those little cars could be pretty rough on them. The car I worked on is primarily for display, so I think the slip fit will be sufficient - and a dab of glue can make it more secure if necessary.

[@albertfox9923]

Hi Ron, Another great video. Once again you have made a frustrating bending problem so simple. What metals do you find appropriate for most of the fabrication work such as this light hosting? And, At a metal bash demonstration we saw the use of stainless steel for a motorcycle tail pipe. Would that process work on a smaller project similar to this housing or would the application of heat cause too much distortion. Thanks again for your great videos.

[@RonCovell]

Thanks so much, Albert. I use 3003 Aluminum, and Drawing-Quality steel for most of my projects. I enjoy working with stainless, but it does have some 'quirks' that make it challenging. It's much more difficult to cut, and it does tend to warp more when welded - particularly with the thinner gauges. One great feature about stainless - it will never rust or tarnish - even with no surface coating.

[@johnhughes8563]

Very interesting, thank you so much .

[@RonCovell]

You are very welcome

[@bdpgarage]

Talented guy!

[@RonCovell]

Thanks!

[@PlaztekNerd]

Great stuff Ron! Is this for our mutual friend Don H ? I miss seeing you around town, but we are loving it up here in Oregon, Gary

[@RonCovell]

Hi Gary. No, this was not a project for Don - he could certainly make these parts himself. I didn't realize you had moved already. Yes, Oregon is a beautiful place. My mom grew up there, near Medford.

[@CraigHollabaugh]

looking forward to it.

[@RonCovell]

Just a few more hours till it launches!

[@VladekR]

Magic, usually magicians don't reveal their tricks 👍👍👍👍👍👍👍👍

[@RonCovell]

I like to show people how to get stuff done!

[@tryphontournesol427]

So much elegance in your work .

[@RonCovell]

What a nice thing to say!

[@ericbarnawell8481]

Great video. What was the gauge of the sheet metal? 20? Also the size of the silica bronze? These techniques would work great on any thin metal repair. Thanks for the techtorial

[@RonCovell]

Yes, I used 20-gauge cold-rolled mild steel. The Silicon Bronze filler rod I used is .045-inches.

[@WaAallE]

It Was very interesting!

[@RonCovell]

I'm glad you liked it!

[@oldsilkhat7893]

Ron, what would be the best method for cutting a tight radius with aviation snips? For example when you made the lower piece that goes underneath the headlight, you cut a half radius. Every time I need to do that it seems like I end up with what looks like multiple slices.

[@RonCovell]

For the part in the video I used a bandsaw to make the cut, to keep from distorting the metal. You can make pretty tight curves with snips, but when doing so you can lose the flatness of the metal, and you may need to hammer it to get it straight. I cover the use of snips extensively in this video: kzbin.info/www/bejne/rmmzdYV3qLJ3jsU

[@jamesa7506]

Did the new assembly match the existing one or did you have to make two new ones? If you did, then is that really a restoration? A fine job nonetheless, my friend! 👍

[@RonCovell]

The original parts were missing, so all I had was the poorly-fitted part someone else made, and the photo of a restored car I found online. To my eye, the ones I made are a pretty good match to the original.

[@jamesa7506]

@RonCovell I thought the photograph was of the original and that you were repairing/restoring the one headlight assembly back to OEM spec. I am mistaken and apologize. Again, sir, a fine job and I apologize for the boldness of my questions. Well done, Mr Covell. Your workmanship throughout your career speaks highly of your skill and dedication to quality that is second to none. May Christ grant you many more years of your exceptional service.

[@jamesa7506]

​@@RonCovell👍

[@jamesmoore5603]

For the already cut piece, would using a rectangular piece underneath, to provide the leverage to do the bend work?

[@RonCovell]

I've never tried that. It MIGHT work, and I think making the rectangular piece from thicker metal might make it work a little better.

[@terrydoss8565]

Mr. Ron, learned a lot on this one. How long did it take? Thanks TD

[@RonCovell]

Terry - hard to count the hours with the camera running - and I made lots of parts I had to scrap.

[@Cor97]

Question: Is the centerline of this part supposed tom be parallel with the floor as the fender is mounted on the vehicle? And if so, how did you assure this?

[@RonCovell]

When the headlight mount is on the car, the bezel is the highest point, and the housing goes downhill toward the rear. The diameter of the headlight bezel determines this angle.

[@dennisschickling2249]

Nice Work. Thanks. #STAYSAFE #PHILLYPHILLY 🇺🇸

[@RonCovell]

Thanks!

[@Iowa599]

How's the reflector mount, & how do you align the lamp?

[@RonCovell]

That's a good question. I was not provided with those parts, so the owner will have to work that out. As you probably know, most pedal cars of this era are used primarily for display, and the majority do not have functioning lights.

[@Iowa599]

@@RonCovell I was thiking of these: kzbin.info/www/bejne/iXXReKJnab1nbK8 ~1/2 scale, running, driving, replicas of 1950's sedans, "Dwarf Cars" on My Classic Cars

[@RonCovell]

Those dwarf cars are REALLY cool! For something like that, I would use an existing light and reflector, which you can find in many different sizes. Motorcycles often use lights smaller than automobiles, and you can find fog light and cowl lamps in sizes even smaller: bobdrake.com/collections/cowl-light?srsltid=AfmBOoplZMQFSJEc2QUMsX01-O2bcI1THgRJ6Lw4M71t7FdnYP297PnQ

[@phamvanlanh82]

Hi Ron Covell, I'm Lanh. I'm in Vietnam. I want to buy the TM Air Hammer #6 (from TM Technologies). Do you sell it? If not, you know where to buy it, please let me know. Thanks

[@RonCovell]

Kent White, the owner of TM Technologies passed away recently, and I don't believe his equipment is available anymore. His website is down. You can make your own hammer. Here is a link that may be helpful: kzbin.info/www/bejne/m5OtqZ2ojbZkmpo One of the features of the TM Technologies hammer is that it could be fitted with powerful Aircraft Rivet Guns, but you could select any power source you desire.

[@phamvanlanh82]

@@RonCovell Thank you very much

[@bertjankosters]

Hero!!

[@RonCovell]

Thanks so much!

[@dennyskerb4992]

👍👍

[@RonCovell]

Thanks for the two thumbs-up!

[@filepz629]

❤️‍🔥

[@RonCovell]

Thanks!

[@rafalrafal8103]

Hello Ron. I watch you in Poland as always and as soon as I receive a notification about your film. I have to write you an e-mail. I want to ask something Regards Raphael

[@RonCovell]

Hi Rafael - you can reach me at: [e-mail]

[@felio_]

That looks complex and impossible... again! haha

[@RonCovell]

I think if you follow each step carefully, it is not really that complicated.

[@U014B]

That kid's gonna be missing many weeks of allowance to pay for this...

[@RonCovell]

Well, if you pay someone a professional shop rate to make parts like this, it is fairly expensive. If you do the work yourself, not so much.

[@dukeallen6562]

Won’t that bezel come off as some youngster rattles down a sidewalk?

[@RonCovell]

Yes, for a pedal car that sees some 'action', I would use some drops of glue to hold the bezel in place. Many of these cars are for display only.