MANUFACTURING PROCESS OF A CUSTOM BICYCLE
Although we have machines that help us to be faster in the production of CNC machined parts, our work methodology is artisanal, each bike is unique and is cut, welded, aligned and painted by hand.
Our workshop is completely self-sufficient, we do all the processes necessary for the bike to be finished here, from shaping the tubes to assembling the components. In addition, customers have the option to come to the workshop and see how the manufacture of their bike or tandem progresses.
1 - BIOMECHANICAL STUDY OF THE CYCLIST
Our work methodology is based on adapting each bicycle to the cyclist in the most precise way possible. Therefore, instead of proposing a standard geometry, we have always opted for “bike fitting”. It is not necessary to carry out this process with us; If you have a trusted center, you can do your biomechanical study there and directly provide us with the measurements of the frame you need.
Bike fitting is a quick and simple option with which, through a form of main measurements, a fairly approximate geometry can be extracted that adapts to the body proportions of each cyclist.
2 - BIKE DESIGN
Once we obtain the final geometry through the bike fitting form or receive the personalized measurements from your biomechanical study, our engineers process it and convert it into the basis on which your frame will be designed.
We have bicycle models for almost all disciplines: XC, road, gravel, enduro, DH, trial and urban. Each model has its own CNC parts and specific tube diameters, which, depending on the case, are placed on the plan with all the exact measurements, just as the bicycle will be mounted on the tooling.
This is how the manufacturing process of all our bicycles begins.
3 - CUTTING OF THE TUBES
We work with a wide variety of tube types, including different materials and shapes. Our main raw material is cylindrical tubes, but we also usually assemble pre-formed tubes from Dedacciai, a well known italian brand. In case the cylindrical tubes have to be shaped we will make use of our own tube forming tools, these tools created by ourselves allow us to give aesthetic shapes to the tubes without having to leave the workshop.
Then we proceed to cut all the tubes by hand looking for maximum precision in order to guarantee a union as compact and rigid as possible between all the components that will form the final bike.
4 - CNC MACHINING
Once we have all the parts correctly designed, through our numerical control “CNC” machines, we start the machining of the corresponding parts. Starting from a metal block, material will be extracted until you have the exact piece.
5 - PLACEMENT ON THE TOOL
We have a tool designed by us which allows us to adjust the lengths and angles of any geometry that is proposed to us.
Once the four main points have been placed and fixed, stem, pipe, bottom bracket and toes, the rest of the tubes will be placed to make the first welding points that will allow us to have the whole frame as a whole.
6 - WELDING
Our welds are the result of many years of experience in this field, welding all types of parts, tubes and different metals. A well-done weld makes bikes stiffer, stronger and less prone to cracking. It also makes the bikes look much more finished.
7 - HEAT TREATMENT
All the metals that are welded reach high temperatures, when these cool, internal tensions are created within the material that can later translate into unwanted breaks. To avoid this we always apply a heat treatment.
On 7000 aluminum bikes, which is what we mostly use, it only takes 72 hours of rest for the frame to be ready to start its useful life. In the case of other types of metals, the type of treatment required may vary. In any case, before the next step, the panel is allowed to pass the appropriate heat treatment hours.
8 - ALIGNMENT
During the whole process, great care is taken to ensure that the frame does not take unwanted twists, which is why it is continuously being aligned during the process.
Even so, after the welds have cooled, and the corresponding heat treatment has passed, a final alignment is made again to ensure that the final position of the frame is completely correct for harmonious operation with all the components that are They will ride on it later.
9 - PAINTING
Paint is a key part of customizing and finishing your bike. That’s why we offer more than 100 colors to choose from when making your design. We paint the paintings in the workshop in a room solely dedicated to painting, to offer the best possible quality.
In addition to specific colors, you can also choose more elaborate designs with specific lines, specific areas or even more elaborate designs like camouflage.
Depending on the design, more than two layers of paint will be applied to be able to add all the colors, once the picture is painted we apply a layer of varnish to guarantee its durability.
10 - ASSEMBLY AND SHIPPING
if you want us to assemble the components, we will order them and they will be previously sent to the workshop. the last step to finalize the bike is to incorporate all the agreed components, leaving it finished and ready to ride and enjoy.
The bike or final frame can be picked up directly at the workshop in Perafort (Tarragona) or we can send it to you at home including the price of this in the final cost of the bike. We ship worldwide!
DO YOU WANT TO CUSTOMIZE YOUR BIKE?
Thanks to our artisan work methodology, we are specialists in adapting our products to the physical needs and aesthetic preferences of each of our customers. If you have a preconceived idea of what you want your bike to look like, don’t hesitate to let us know.
