If you can't find it... handlebar end plugs

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Clydesdale Scot
Posts: 1958
Joined: Tue Mar 03, 2009 12:55 pm
Location: Adelaide, SA

If you can't find it... handlebar end plugs

Postby Clydesdale Scot » Mon May 14, 2018 5:02 pm

In another of the ongoing stories
If you can't find it... Shockstop 'honking' rubbers
If you can't find it... cable bands
I was wanting some period handlebar end plugs. I had some Velox expander plugs, but they came later to the period I was after.
Danny found some used Shockstop bar end plugs
viewtopic.php?t=59137#p1391179
and Quang rotated the profile and 3D printed one.

About the same time I purchased a NOS set. Not cheap, and nor was the postage from the UK.
Then I had to learn how to make the mould and cast them.
David's thread on Bike Forums has been an excellent guide
How to make reproduction Vittoria hoods and his photos on his Flickr album
https://www.flickr.com/photos/68123172@ ... 2070020831
For those on Classic Rendezvous, David has recently shown his latest project, reproduction Vittoria handlebar Plugs.

I had a vacuum pump that I use for casting leather saddles, so with a few extra bits I had a device to put the mixture under a vacuum to minimise any trapped air bubbles.
But I also wanted a pressure tank to place the cast item under pressure to squeeze down any remaining bubbles before the urethane solidified.
Recently I bought a pressure tank at a good price.
So no more excuses.
Time to play... with Duplo and a Lego board and clay.

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Clydesdale Scot
Posts: 1958
Joined: Tue Mar 03, 2009 12:55 pm
Location: Adelaide, SA

Re: If you can't find it... handlebar end plugs

Postby Clydesdale Scot » Mon May 14, 2018 5:12 pm

Imagemould casting by philip.knight, on Flickr

I created a bed in the special modelling clay to raise the bar end plug up. I then needed the fill in and around the original to exactly half way up the sides. I used the original parting line clearly evident. I added some depressions to help locate the two halves and added the silicone.
Then waited for that to set overnight.
Carefully removing the Duplo sides to the mould, then carefully removed the modelling clay.
Flipped the cast top and the original plug over, sealed up all the Duplo joins, applied a release agent so the silicon wouldn't stick to the previously cast piece and then cast the complementary half.
I had no idea if the first half had work, or was so full of bubbles to render it unusable.
Mould silicon is not cheap.

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Clydesdale Scot
Posts: 1958
Joined: Tue Mar 03, 2009 12:55 pm
Location: Adelaide, SA

Re: If you can't find it... handlebar end plugs

Postby Clydesdale Scot » Mon May 14, 2018 5:30 pm

This morning, with some trepidation, I removed the Duplo sides and then gently prised the two mould sections apart.
The release agent worked.
Then I removed the original plug, and carefully inspected the result.
Imagemould opened by philip.knight, on Flickr

You can see the original has the parting line flashing evident, and this is seen on the red halves to the mould.
Thye half on the left was the first half moulded and the half on the right is the second half and is an exact replica of the modelling clay shape I needed to make.
I need to clean up the remaining modelling clay, and cut through the injection hole and the vent sprue.
I was very pleased with the accuracy of the mould.
Just like the YouTube videos!
And now I need to wait for the casting urethane to arrive at the casting suppliers.
So there are more instalments to come.

Looks like I can play with my kid's Duplo and Lego base until they produce some grandchildren.
Then I can show the grandchildren how you really play with Duplo and modelling clay.

flying dragon
Posts: 24
Joined: Sat Sep 15, 2012 2:15 pm

Re: If you can't find it... handlebar end plugs

Postby flying dragon » Tue May 15, 2018 9:20 am

Awesome!
I made very similar moulds when I studied sculpture at art school. We were pouring wax into the moulds to then cast bronze.
Fun project!

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