Zundapp Pushie, (on going project)

Discuss your bike, modifications etc.
Post Reply
Pushie Pirate
Posts: 42
Joined: Thu Aug 08, 2013 9:09 pm
Location: Lord Howe Island, NSW Tasman Sea.

Zundapp Pushie, (on going project)

Post by Pushie Pirate » Thu Sep 12, 2013 6:01 pm

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.
Image Image

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.
Image Image

Bit more planning with pencil on paper.
Image Image

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

Donor bike and some bits of steel for the frame.
Image Image

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

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

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

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.
Image Image

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.
Image Image

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.
Image Image

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.
Image Image

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

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.
Image Image

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

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

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

Image Image

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

Youngblood
Posts: 375
Joined: Wed Oct 24, 2007 1:48 pm
Location: North-Eastern suburbs- Adelaide

Re: Zundapp Pushie, (on going project)

Post by Youngblood » Thu Sep 12, 2013 10:00 pm

Well done so far, I'm a big fan of your work, keep it up and keep posting your pictures
8) 8) 8) 8)
Youngblood

Bearcx
Posts: 1894
Joined: Thu Oct 18, 2007 12:31 am
Location: Gawler, Sth Aust
Contact:

Re: Zundapp Pushie, (on going project)

Post by Bearcx » Fri Sep 13, 2013 11:32 am

Good on ya, for thinking outside the square. Watching with interest.
The brave may not live long, but, the cautious do not live at all.

Pushie Pirate
Posts: 42
Joined: Thu Aug 08, 2013 9:09 pm
Location: Lord Howe Island, NSW Tasman Sea.

Re: Zundapp Pushie, (on going project)

Post by Pushie Pirate » Sun Sep 15, 2013 5:44 am

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.

Image Image
The chrome fenders will be painted.

Image Image

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

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

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
Posts: 375
Joined: Wed Oct 24, 2007 1:48 pm
Location: North-Eastern suburbs- Adelaide

Re: Zundapp Pushie, (on going project)

Post by Youngblood » Sun Sep 15, 2013 10:24 am

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

Prof
Founder, Choppers Australia
Posts: 5795
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
Contact:

Re: Zundapp Pushie, (on going project)

Post by Prof » Sun Sep 15, 2013 7:29 pm

Can you weld valences to the guards to bulk the ends of the bike up a bit?
Chopit'nrideit... Prof

Pushie Pirate
Posts: 42
Joined: Thu Aug 08, 2013 9:09 pm
Location: Lord Howe Island, NSW Tasman Sea.

Re: Zundapp Pushie, (on going project)

Post by Pushie Pirate » Mon Sep 16, 2013 6:47 am

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!
Image Image

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.
Image Image

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.
Image Image

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

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.
Image Image

Prof
Founder, Choppers Australia
Posts: 5795
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
Contact:

Re: Zundapp Pushie, (on going project)

Post by Prof » Mon Sep 16, 2013 10:08 pm

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

Youngblood
Posts: 375
Joined: Wed Oct 24, 2007 1:48 pm
Location: North-Eastern suburbs- Adelaide

Re: Zundapp Pushie, (on going project)

Post by Youngblood » Mon Sep 16, 2013 10:29 pm

Looking good!!!! :) :) :) :)
Youngblood

Cromag
Posts: 2563
Joined: Tue Nov 15, 2005 10:58 am
Location: NSW

Re: Zundapp Pushie, (on going project)

Post by Cromag » Sat Sep 21, 2013 2:14 pm

Nice work, Über Cool......I think it looks better without rear seat too.
Does not work or play well with others
Loud pipes save lives
"These are not the Droids you're looking for"

Pushie Pirate
Posts: 42
Joined: Thu Aug 08, 2013 9:09 pm
Location: Lord Howe Island, NSW Tasman Sea.

Re: Zundapp Pushie, (on going project)

Post by Pushie Pirate » Thu Feb 27, 2014 4:59 am

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

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

Image Image

Image Image

Bit of bondo and some sand paper got me close.
Image Image

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

Image Image

Youngblood
Posts: 375
Joined: Wed Oct 24, 2007 1:48 pm
Location: North-Eastern suburbs- Adelaide

Re: Zundapp Pushie, (on going project)

Post by Youngblood » Thu Feb 27, 2014 10:10 pm

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

Post Reply

Return to “chopper push bike chat and pics”