MANUFACTURING PROCESS OF A CUSTOM BICYCLE

We manufacture our bikes and tandems in our own workshop in Tarragona, controlling the entire production process in-house. We start with high-quality 7020 aluminium imported from Germany, in the form of tubes, plates and sheets, and transform it according to our own designs through CNC machining, preparation, welding, alignment, painting and final assembly.

This way of working allows us to own the entire process, continuously improve our products and adapt each bike or tandem to the needs of every customer. We do not work with generic frames or external production: every project is manufactured and completed inside our workshop.

1. Rider body measurements

Our working method is based on adapting each bike to the rider as precisely as possible. For this reason, instead of offering a standard geometry, we have always focused on bike fitting. This process does not need to be done with us; if you already have a trusted bike fitting centre, you can complete your study there and send us the exact frame measurements you need.

Bike fitting is a quick and simple way to obtain an accurate geometry based on each rider’s body proportions, using a form with the main body measurements.

2. Bicycle design

Once we obtain the final geometry through the bike fitting form, or receive the customised measurements from your biomechanical study, our engineers process the information and use it as the basis for designing your frame.

We offer bike models for almost every discipline: mountain, road, gravel, enduro, DH, trials and urban riding. Each model has its own specific CNC-machined parts and tube diameters, which are placed on the technical drawing with all the exact measurements, according to how the bike will later be assembled on the frame jig.

This is how the manufacturing process begins for all our bikes.

3. Machined parts

We have our own CNC machining centre and lathe, where we continuously manufacture specific parts based on our own designs. Starting from aluminium blocks, we precisely machine components such as dropouts, joints, mounts, linkages and reinforcements, which will later become part of our frames.

This constant production allows us to always have the necessary parts ready, so our team can move forward with the fabrication, welding and assembly of each frame in an efficient and controlled way.

4. Tube cutting and positioning

Our main raw material is round aluminium tubing, which we shape ourselves, although in some bike models we also use pre-formed tubes from specialised brands such as Dedacciai.

Each frame is built individually on our own frame jig, allowing us to adjust lengths and angles according to the specific geometry of each project. Once the main parts are positioned, such as the head tube, bottom bracket and dropouts, we measure, cut and adjust each tube so it fits precisely.

When all the tubes are correctly positioned, we make the first tack welds to hold the structure in place and maintain the exact geometry before the final welding.

5. Welding

Our welds are the result of many years of experience working with all kinds of parts, tubes and metals. We work with skilled welders specialised in aluminium welding, using the TIG process to ensure precise, strong and well-finished joints.

A good weld is essential to make the frame stiff, durable and less prone to cracking, while also giving each bike or tandem a clean and professional finish.

6. Alignment

Throughout the welding process, we take great care to prevent the frame from developing unwanted torsion or deformation. For this reason, alignment is continuously checked and adjusted as the fabrication progresses.

Once the welding is complete, and before the joints fully harden, a final alignment is carried out to ensure that the frame’s final position is correct and precise.

This step is very important, as alignment must be done at the right moment. Once the welds have fully hardened, the key points of the frame become permanently fixed.

7. Heat treatment

All welded metals reach high temperatures during the welding process. As they cool down, internal stresses can form within the material, which could later lead to unwanted failures. To prevent this, we always apply the appropriate thermal treatment.

For 7000 series aluminium frames, which is the material we mainly use, the frame only needs 72 hours of natural ageing at room temperature before it is ready to begin its working life. For other types of metals, the required treatment may vary.

8. Painting

A key part of personalising and finishing your bike. That is why we offer more than 100 colours to choose from when creating your design.

We paint our frames in-house, in a dedicated paint room within our workshop, to ensure the best possible finish quality.

Depending on the design, more than two layers of paint may be applied to include all the required colours. Once the frame is painted, we apply a clear coat to protect the finish and ensure long-lasting durability.

9. Assembly and shipment

We have a network of suppliers and a purchasing system that allows us to order the specific components agreed for each project. These components arrive at our workshop in advance and, once the frame has been manufactured and finished, our mechanics carry out the final assembly, leaving the bike fully built, adjusted and ready to ride and enjoy.

The finished bike or frame can be collected directly from our workshop in Perafort, Tarragona, or we can ship it to your home, including the transport cost in the final price. We ship worldwide!