Zundapp Pushie, (on going project)

[Pushie Pirate]

Haven't been on for a while thought I would share my latest on going project, have been having a go at building
a push bike version a Zundapp Motorcycle used by the German army during WW II will be sort of stand off scale.

So sketch first and a bit of planning.


Been a model maker for some time, so got a 1/24th scale kit of the bike to get an idea on some of the details.


Bit more planning with pencil on paper.


Drew up a scaled up plan for the frame, just slightly smaller than a real one.


Donor bike and some bits of steel for the frame.


So here is the front section of frame, mounted up on a jig of plywood with nails to hold it's position.


Multi pie cuts to get that aggressive curve in the lower frame, will be tricky to weld. The top end
not so difficult


Here are the frame parts pretty much ready to be welded together, hopefully soon.


So here is a bit of a mock up of the beginnings of this bike. Yep she will be chunky, yep she will be
a little heavy but hey weight will mean momentum right! Took a bit to hold all this together and get
her welded.


Here is how I got around those fine pie cuts front lower frame, covered them with a plate and welded
the edge of the plate.


Here is the front end, that little stork will be for the gear lever. Will run the gear and brake cables
down the centre of the upper lengths.


The rear of the frame just behind the seat post to the start of the donor frame section that I used.
Had a few headaches getting this section right, you can see my finger pointing to the rear of the
frame where I put a cut to bend the section down.


The bars are some stock cruiser bars with a short length extending them slightly.


No fancy mig or tig welder for me, old school arch welder low amps and 2mm rods and blast a few
holes then fill them! Most people who have mig or tig welders here have real problems with feed
as the salt air creates corrosion on the coil of wire and it doesn't feed well, none of these problems
with arch. Now take it easy on my welds folks, far from a master!

Here she is alongside a picture of the real machine along way to go but getting there.


So using plywood to help make up motorbike bits, got a bit of sanding ahead of me!


Yep will have two seats as per the real machine, plan to have the rear one swap-able with a carrier.


Using an old motor bike headlight surround and that's a VW oil filler cap as a the tank cap.




Found a good book with some great detail shots, slowly getting there.

[Youngblood]

Well done so far, I'm a big fan of your work, keep it up and keep posting your pictures

[Bearcx]

Good on ya, for thinking outside the square. Watching with interest.

[Pushie Pirate]

Got a bit done over the weekend here she is as she stands today all mocked up, at least she looks a bit like the real thing.


The chrome fenders will be painted.



Working light is just a cheapy torch, the wartime bikes had shades so they couldn't be seen so well at night.


I took a pic with the rear seat off, looks okay like this I think.


From here a bit more welding, and a heap of sanding and filling of the ply bits, then paint and assembly
can see the glow at the end of the tunnel!

[Youngblood]

I like it better with the rear seat, can't wait to see the finished product.

[Prof]

Can you weld valences to the guards to bulk the ends of the bike up a bit?

[Pushie Pirate]

So you mean bulk up the guards a bit, yeah it would be nice but the tin is so
thin, I only have a stick welder, would just blow it to bits even on low amps.
She is sort of stand off scale and I have learnt to make sacrifices here and there
for the sake of making the things ride-able. Managed to get more done yesterday.

Slow progress, seem to have done a lot but doesn't look like much, lots of filling
and sanding to get to where she is now at least it is all one colour!


She will be a two seater like to original, as I said above may spend sometime as
a single seater as I think she looks okay with out the second seat.


That's a Honda CT 90 headlight surround and an early VW oil filler cap topping off
the fake tank. Interesting little connection here Ferdinand Porsche who designed
the VW Beetle also worked for Zundapp, yep trivia but I like that sort of stuff.


The little box on top of the tank was used for storage on the original, seats will
be covered eventually.


The original had heat shields on the muffler, I am using them to stop the passengers
feet getting stuck in the spokes.The foot pegs again from a Honda CT90.

[Prof]

It has come up well. Have you thought of ply mudguards? 15mm curve and 5 mm sides would allow some roundness on the edges.

[Youngblood]

Looking good!!!!

[Cromag]

Nice work, Über Cool......I think it looks better without rear seat too.

[Pushie Pirate]

Have got back into a few details on this one, used an old trailer hitch for the passenger handle.


Really wanted a taillight close to to original, so scratch built this, an old can and some plywood.






Bit of bondo and some sand paper got me close.


Finally a shifter from a couple of VW Beetle heater cable levers.

[Youngblood]

As I said before love your work, think you are outdoing yourself on this project.