Factory Tour: Ruckus Components – Carbon Fiber Repair and so much more

Ruckus Componens Shawn and Graham

What do you get when you mix a wacky engineer who specialized in composites with a guy who used to work in hospitalities but just happens to lay down killer paint work?  You get Ruckus Components! I recently had the opportunity to spend the afternoon with Shawn (left) and Graham (right) in their Ruckus Components lab.  They have created a shop environment that  is a somewhat of a mixed bag.  You will find a bit of mad science, wacky engineering, and custom fabrication / paint, along with carbon fiber repair work.

Ruckus Components Calfee Broken Headtube

The boys at Ruckus primarily focus on carbon fiber repair.  Most will find that the cost of repair is a lot less than a crash replacement frame.  So, if you happen to leave the bike on the roof of your car while entering your garage you can take it over to Ruckus and see what they can do for you.  They will inspect any carbon parts (frames, forks, wheels) and let you know if the repair is possible and the general cost ahead of time.  Typical turn around time is about two weeks.

For the rest of the images, including a customized Enve Road 1.0 fork, click through.

Ruckus Components Custom Enve 1.0 Road Fork

Ruckus Components Custom Enve 1.0 Road Fork Wire Routing and Fender Eyelets

 

 

 

 

 

 

 

 

 

 

Ruckus Components Custom Enve Road 1.0 Fork Fender Eyelets Closeup

It is not uncommon to find some nice one off custom work laying around the shop.  While there, I spotted this fork.  It happens to be an Enve Road 1.o that has been modified with fender eyelets and cable routing for a generator hub.  The fork is not quite finished yet.  Graham finished spraying the clear coat, but it still needs a good standing and polishing.  When done, the entire thing will look stock.

Ruckus Components Custom Front Rack 3

Why go with wood planks on your rack when you can have custom carbon fiber with engraving?

Ruckus Components Modified Zipp Vuma Cranks FrontRuckus Components Modified Zipp Vuma Cranks Rear

 

 

 

 

 

 

 

 

 

 

What do you do with a broken Zipp Vuma crankset?  You give it to Shawn who then cuts it apart, attaches it to a single ring, and re-wraps the carbon.  Next it will get cleaned up and polished to become one of the lightest single ring cyclocross cranksets in existence.  Sure there are no chain ring bolts, but honestly, when you have the shop they do you just cut it off and mold on a new one when needed.

Ruckus Components Graham Carbon Fiber Cowboy Hat

What do you do when you get bored at work?  Graham made a carbon fiber cowboy hat!

Ruckus Components Carbon Bash GuardsRuckus Components Fender Pile

 

 

 

 

 

 

 

The guys have designed and built chainring guards as well as a pile of fenders. Unlike others, the fenders are curved, not flat.  The mounting hardware for the fenders are cut on a water jet and the struts are carbon rods.  It makes for a very stiff full coverage fender for your road bike.  They are not in full production yet however.

Ruckus Components Vinyl for DecalsRuckus Components Customer Vinyl Decal

 

 

 

 

 

 

 

When doing repair work, often the frame decals need to be matched and replaced.  They keep around a pile of different colored vinyl, as well as a sample book so they can match just about any decal.  The decals are printed, cut by hand, and applied in house.  Custom decals are no problem either.  You can have a phrase added, logos applied, or even custom graphics for your custom steed.  While not pictured, they can also do an amazing job matching the factory paint so that repair work blends right in.

Ruckus Components Raw Carbon TubeRuckus Components Raw Carbon Fiber

 

 

 

 

 

 

Ruckus Components Samples Board 2Ruckus Components Raw Materials

 

 

 

 

 

 

 

 

When you are in the carbon fiber repair game, you need a pretty diverse stock pile of different types of raw carbon.  Around the shelves of the Ruckus lab you will find different carbon fiber weaves, different modulus, as well as kevlar (the colorful ones), and even baslat fiber (not pictured).

Don’t let that nice race bike sit in the shed any longer just because the chain stay is broken or the top tube is damaged.  Get it down to Ruckus, then get it back on the road again.  And, while Ruckus is a local (for me at least) Portland company, you can ship your frame  to them for inspection and repair work.

 

Comments

Rob - 07/25/11 - 11:31pm

Basalt is cheap with properties a bit better than f/glass. Very nice to work with. Why on a bike though compared to carbon or kevlar? Cheap, drapes well and has excellent thermal properties.

eddyadams - 07/26/11 - 2:28am

These dudes fixed my carbon frame and it looks damn good. They got it back to me really quick and are super nice guys.

bikeryder85 - 07/26/11 - 7:35am

man that bash looks sweet…esp at only 25 grams!

Hoodlum-Z - 07/26/11 - 9:45am

@ Rob

I read on another site that Basalt is good at absorbing road buzz, that is why Canyon use it on one of their seatposts.

http://www.cyclingnews.com/reviews/photos/canyon-ultimate-cf-slx-team/136268

Pants and Jacket - 07/26/11 - 10:51am

“Cheap, drapes well and has excellent thermal properties”

That’s what I look for as attributes for my boxer shorts.

Shawn - 07/26/11 - 3:12pm

@Rob and Hoodlum
we like to experiment with a lot of different materials down here, Basalt is pretty cool stuff. Affordable and increased elongation over CF. Mixing/matching different materials is the best part of composites!

@eddyadams
thanks for the kind words, we are definitely giving it our all down here!

ThinkBikeminded - 07/28/11 - 10:38am

Is that a Calfee bike that they’re repairing?

Nick Burklow - 07/28/11 - 8:41pm

@ThinkBikeminded Yes, it is a Calfee. Though, it was not Calfee’s fault. It was on a roof rack at the same time the vehicle was trying to enter the garage. Accidents happen, but its good to have people like the guys at Rukus who can fix a bike that was very much loved by its owner so they may ride again.

Post a comment:

Comment sections can be a beautiful source of knowledge, conversation and comedy. They can also get pretty ugly, which is why we've updated our Comments Policy. If your comment isn't showing up or suddenly disappears, you might want to check it out.