Build a Custom Bone Kickstand With Cast Aluminum

So I got ahold of a late 80's model GT performer frame, I finally decided to build it up. I used some older parts that I had and ordered up some newer GT parts. The mounting for the old school brakes was left bare due to the newer style rims. So after thinking for a while I thought I could build and mount a slick custom kickstand. Granted, this will not work for everyone but I'm sure you could modify the design to fit other bike designs. For this design I decided to make a Bone mold and melt scrap aluminum into it. This is potentially dangerous so take every precaution and use proper safety!

Step 1: Parts and Tools

Parts: scrap aluminum (to melt in the mold), 3/8" aluminum for the bracket, round stock steel for mold support, 5/16" bolts for mounting and stops, 3/8" bolt for main kickstand, scrap wood for mold body, joint compound, misc. washers and springs. * I used 2 ball bearings,a magnet and 1" steel rod to make the bone model *. Tools: belt sander, grinder, drill press, torch and wrenches.

Step 2: Building the Mold

With scrap wood make a frame to hold the mold. Mix the joint compound pretty thick but evenly. Pour into the box and cover with Saran Wrap. Gentle place what your molding on the Saran Wrap and let dry over night.

Step 3: Melting and Pouring

This was trickier then I thought it would be. My mapp gas torch melts aluminum great but the amount of aluminum that needed to be liquid was a greater amount that my torch could keep at that temp. Luckily my dad has a oxy- acetyline torch. Suspend the steel rod in the mold with thin wire. Melt the aluminum, it needs to almost glow, then pour into the mold and let cool for an hour. Once cool remove from the mold.

Step 4: The Bracket

Use aluminum bar stock and mock up where you want the kick Stand to be. Draw the hole placements and drill them out on the drill press. You might have to bend the bar stock in a vice as well.

Step 5: Springs, Bolts and Nuts

I had to look pretty long for the right length spring and one that is designed for this type of use. You might find some other spring, nuts and bolt that work better for you.

Step 6: Test Fit

After I got the bracket mounted I used vice grips to lock in the angle I wanted. Marked out what needed to be drilled, then drilled the holes. The spring attaches to the existing bolts, as pictured.

Step 7: Get It Together

Finish drilling and put it all together to ensure proper function. Use locktite to keep the bolts secure. You don't want this bad boy falling off while riding!

Step 8: Painting

I painted the theme of the bike chrome, black and red. The sprocket was painted in the same manner. I kept the bone white, it pops well and looks good. I used self etching primer, black, red and white enamel paints.

Step 9: Add Shrink Tubing

I used heat shrinking tube to act as a buffer and hide the screws I used for stops.

Step 10: Final Thoughts

This thing functions perfectly! It's a vey custom piece that works well with the theme and adds a great touch! Thanks for looking, please ask any questions you have. If you like this project (or any of my other projects) please vote!