Sunday, March 18, 2012

Kickstand for 1949 Ducati Cucciolo

To make a replica of the broken kickstand off my 1949 Ducati Cucciolo

When I inherited the cucciolo I noticed that one leg of the kickstand was broken off. A previous generation had drilled two holes through the stub of the broken leg and riveted a bent piece of flat iron to it. It was pretty wobbly but I guess it kept the bike up.

First thing I had to do is take the kickstand off which was easy. Two screws and a spring tied it together then it needed a very serious clean with the parts washer. There was over 40 years worth of oil, grease and dirt stuck to it. The cleaning took a good 15 minutes. Couldn't have done it without the parts washer fluid.

After it was clean and dry, I mixed up some autobody putty together and patched up the holes that were drilled and some of the worn off aluminum from the bottom of the kickstand leg.

Then I used some of the leftover 2 component reo-flex polyurethane rubber (shore hardness 60A) that I had bought a couple of years ago (when I made the concreted stamping pattern for my driveway) to cast a negative of the good kickstand leg. Once that cured for about a day, I removed the aluminum leg and filled the negative cavity with another batch of the rubber to create the positive copy of the leg.

Once the positive copy of the good leg had cured for about two days I cut it to length and glued it to the broken kickstand with some regular polyurethane glue.

With that "fixed" pattern I was able to create a mould of the kickstand. After firing up the foundry furnace and melting about a pound of aluminum I poured it into the mould, waited half an hour for it to cool down and extracted it from the sand.

A little bit of grinding was left and voila! Here's the replacement kickstand for my "bike"!


Right after pulling the casting out of the flask

Originally fixed kickstand leg
The broken kickstand taken off the cucciolo and all cleaned up
Using polyurethane rubber to create a negative of the good leg
Filling the negative with polyurethane rubber to create a copy of the good leg

After I filled in some holes with auto body filler and glued the rubber copy of the good leg to the broken side
Now I could use the "fixed" kickstand to create a mould
Cleaning up the casting after I pulled it out of the flask
Comparing the old broken/fixed kickstand with the new one
Another angle

Foundry & foundry tools, grinder, hammer, hacksaw

2 component Reo-flex polyurethane, autobody putty, mold release agent, polyurethane glue, foundry materials

$3.50 (for 1lb of aluminum and some propane)



Success! All the way around. This is incredible!


Ursi said...

Well, I guess building your own foundry was worth it! congrats! So now that this is done, what's next on the list for the cucciolo, and what's next for the foundry? I'm sure you'll keep us informed - in detail.
Love you Chris,

Sir Rudiger said...

You amaze me! It looks fantastic!

wk-eigenheer said...

Let kids explore their surounding and let them their imagination runn.... and they wache their dad working and thinking of improvements... I think then that kid will never stop to think , may be I can make it work.... ?? ! ? ! ... and it worked !!!!!!!!!!!!!! Like new ! No, it is brand new , home made , all by your self.... !!!! Gratulation Christian.
The stretched nerves from the mom of long ago of this "boy" feels allmost a bit proud.... Love you my son.

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