0. I have a bike with Xpedo pedals, and no kickstand
1. I would rather have my bike stand while I go buy some satay, but I didn't want a stand attached permanently to the bike
2. I also have lots of aluminium tubes left over from other projects
Bike stand must be light, easily carried in a backpack next to my lock, easily attached and removed,
Step 1: Material and Measurements
I am using 16mm OD aluminium tubes. The ID can be between 10 to 12mm. You need two measurements from your pedal; the width, and depth. My Face Off pedals are about 80mm in depth and height. You will also need to measure the distance between the edge of the pedal and the ground when your bike is at a stable resting position. For my bike, it's about 10cm.
Cut and mark your tube. For my pedal/bike, the measurements are 75mm, 100mm, 80mm, 100mm and 75mm (pedal depth, distance to ground, pedal width, distance to ground, pedal depth)
You should file down any shape edges right after cutting. You don't want sharp edges later when you start bending the tube.
Step 2: Flattening the Tube
In order to bend the tube, I am flattening the pipe in certain places to accommodate the bend, and also to insert the stand into the pedal. The Xpedo pedal clearance is between 10 and 7mm. The flattened parts of my stand is 6 - 7mm.
Start by bending the middle part. You need to fatten the middle part, but extend the flattened portion about 10mm beyond the bending point. This helps you bend it easier without snapping off the tube.
Step 3: The Middle Bend
I start by clamping down the flattened portion, with the vise edge at the bend mark. This allows me to bend usually about 45 degrees before the tube snaps.
Release the stand at 45 degrees, push the tube forward by about 5mm (which is why I allowed a 10mm distance when flattening earlier), and bend further.
Important points about bending tubes:
2. Use body weight; lean
3. Avoid sharp edges (hence, the filing earlier)
4. Wear gloves
Step 4: Bending the Ends
These ends would be between 45 and 60 degrees. You may need to flatten these ends more to fit into the pedals easily.
Remember the 10mm allowance when flattening.
Step 5: Fit and Test
Finally, fit the stand in the pedal and test. You may need to go back to the bench vise and adjust a little to ensure the fit is correct. For fitting, there are two concerns:
1. Easily installed and removed (adjust end pieces, make sure both flat ends are aligned)
2. Bike is steady (adjust the bend angle)
Remember to do any adjustments at this stage really slowly. The flattened parts allowed bending in one axis, but limit in others.
Step 6: Using the Stand
To use the stand, insert it into the pedal, and turn the crank until it is BEHIND the vertical axis. Then just rest your bike on the stand.
For the record, this stand weighs in at under 80g, or around 2.5oz.