Posts in the category Factory Tour

Factory Tour – Guru Cycles, Part 3: Titanium Frame Building, Painting and Finishing (UPDATED)

Guru Factory Tour - titanium frame alignment check

So far, we’ve taken a pretty close look at how Guru Cycles designs their custom bikes and preps the carbon frames in Part 1 and how those frames come together in Part 2. Now, we get to show you the other side of their business with the steel and titanium frames. Then the finishing and painting process that gets them ready to ship.

Shown above is a titanium frame in their digital alignment table. The spring-loaded “pokers” holding up the seat tube are wired into the system and show how far they’re extended compared to the clamp holding the bottom bracket shell. They can be moved to check any part of the frame, letting the welder confirm alignment after tacking and welding.

But how does it get to this point? Put on those safety goggles and come on in…

UPDATED: Guru’s response regarding ti welds added to bottom of post.


Factory Tour – Guru Cycles, Part 2: Building a Carbon Bicycle Frame

Guru factory tour - carbon fiber bike construction

In Part One of our Guru Cycles Factory Tour, we showed how the design of the bikes goes from customer order through to a pile of tubes ready for assembly. Mostly, anyway.

Here in Part 2 we’ll finish the process and show how everything comes together to form a complete frame. I’ve seen plenty of carbon fiber bicycle manufacturing in our 5+ years of Bikerumor’s existence. Each time I head to a factory, I wonder what could be new? What could the next builder possibly do that’s different from all the rest. What’s amazing is that virtually everyone manages to surprise, and Guru’s no exception.

First, there’s the unique cut of the carbon swatches that make up the frame. It’s the most visible feature of their Photon bikes and gives it a slick sea snake appearance. Under all that carbon, though, is another very cool construction process I’d not seen before…


Factory Tour – Guru Cycles, Part 1: Office Visit, Carbon Bike Design & Stress Testing

Guru Factory Tour

For quite some time we’ve been talking to Guru Cycles about visiting their headquarters and factory near Montreal. Following Interbike, we finally made it happen, giving us the opportunity to see close up how they make the amazingly light ~670g Photon HL carbon frame. I even got to ride one, as well as see how they come together from the time you talk to your shop until the time it’s boxed and shipped. And every last bit of the frame is made there in their own facility. Rolls (not tubes, mind you) of prepreg carbon comes in, frames go out, and that goes for all of their carbon bikes, not just the top of the line HL.

They also make titanium bikes, which will be the subject of Part 3. Here, and in Part 2, we’ll show you how the carbon frames are designed, made and tested, along with an overview of their entire operation. Come along, join the ride…


Factory Tour: Hero Bike’s DIY Bamboo Bicycle Workshops & Semester Carbon/’Boo Campaign

Hero Bike Factory Tour storefront

We’ve written about Hero Bike a couple times now, first to showcase their Semester bike Kickstarter campaign, then about their build-a-bamboo-bike workshops and kits. Over the Thanksgiving holiday, we took a detour from our Greensboro, NC, office to their Greensboro, AL, shop to see how they make the bikes and kits from locally sourced bamboo. And by local, we do mean local. All of their bamboo comes from within a five mile radius of the shop. They grow some on their own land and harvest it from locals’ properties.

Hero Bike was started by the HERO group, a community program originally developed to give at-risk youth something productive to do and, now, as a job training program. Indeed, Mike Gillis, the sole hero present on Thanksgiving Eve found out about the job but had to apply through AmeriCorps to get it. It’s one of several businesses under the Hero umbrella, and their neighbor business assists with the DIY bike building kits that ship out to home tinkerers.

The two bikes they build here -the pencil shaped Semester and the DIYers- couldn’t be more different, showcasing an entirely new way to make bamboo/carbon tubes…


Headquarters Tour: Crank Brothers – Company Profile, Inside Look & Original Prototypes!

Crank Brothers headquarters tour - reception

The lobby of Crank Brothers’ new offices, conveniently located just minutes from the trails around Laguna Beach, CA.

Crank Brothers started in 1997 with the Speed Lever, a card table and a trip to Interbike’s basement.

Well, actually, it started out with the notion of designing products, patenting them and then licensing the designs. It worked once, with a hydration system that was licensed to Bell Sports and became Hydrapak.

The story is their friends constantly got cofounders’ Carl Winefordner and Frank Hermansen names mixed up, so they combined them and just called them “crank”. Hence the first part of the brand name. They met while working for a scuba diving products company. They enjoyed working together and eventually both tired of the corporate culture at a large company. They quit and did freelance snorkel and related product design for a while, but cycling was the passion. Frank is the designer, Carl’s the engineer.

The Speed Lever was inspired by the tools used for car tires, and the idea was born during a night ride when they had to change a tire. Like all of their products, they start out as a solution to a problem they encountered and couldn’t solve with existing products.

At that 1997 Interbike, they handed out 4,000 Speed Levers and a brand was born. It was never envisioned as the high design, global company they are today, and it certainly wasn’t overnight. After the lever, they designed a high/low pressure switch for a mini pump. It was called the Power Pump, and it came out in 1998 along with a couple mini tools.

In 2001, they introduced the Eggbeater pedals, and that’s when things got interesting…


Factory Tour: K-Edge Machine Shop – Garmin Mounts, Prototypes, Gun Stocks & Blades!


K-Edge started as a single chain catcher to save founder Joe Savola’s wife, Gold Medalist Kristin Armstrong, from dropping her chain during the Beijing Olympics. The venue had a course very similar to their hometown hills in Boise, ID, with the slight declines leading up to the climbs. Climbs steep enough to require shifting from big ring to little, the perfect opportunity for a medal-winning bid to fall along with the chain. Savola’s friend, Eric Jensen just happened to own a machine shop, so they made a few for her bikes.

Her team mechanic at the time called them Kristin’s Edge. He then moved to a Pro Tour road team and ordered 45 of them. Eric replied that they only had three. After a bit of persistence from the team, they decided to make them and Kristin’s Edge became, simply, K-Edge. The boys celebrated with pizza and beer from the order’s proceeds. Then they got a little press and a business was born. That was 2009.

Come 2011, they introduced Go Big GoPro mounts and got a bump. But it wasn’t until 2012′s Pro Garmin Mount that business really started booming. And booming it is – click through for a full tour of the K-Edge machine shop and see how all the parts (and some other really cool stuff – and Prototypes!!!) are made…


Quick Tour: Felt’s Southern California Headquarters

Felt Headquarters Tour 2013 (2) sensored

As a small company out of Irvine, California, Felt’s motto has always been the same – not to be the biggest bike company, but the best. Born out of Jim Felt’s knack for building the fastest time trial and triathlon frames long before aero was the new black, eventually Jim teamed up with Bill Duehring and Michael Mullmann to “build a bicycle brand dedicated to technological innovation and unmatched quality.”

Today, Felt as a company has a complete bicycle line touching nearly every style of bike, all run for the most part out of their modest Southern California digs. Take a quick tour of Felt’s home base, after the break.


Calfee Factory Tour: Part Three – Gyrocopters & More

Calfee Bicycles Factory Tour and Molnari gyrocopters

So far, we’ve shown you how Calfee makes their carbon fiber bicycles virtually entirely in house (Part One) and some of the very first bikes up to the latest in carbon tech and bamboo/wood bikes (Part Two). We even had the very first look at their new Manta endurance road bike.

Now we conclude our tour with a look at the Molnari gyrocopters, which Craig Calfee has ownership in and lends his knowledge of bicycle parts and construction, plus another interesting little side project we spotted in the workstand…


Shinola Bicycles – Headquarters Tour, Store Grand Opening & Brand Overview

Shinola Bicycles concept store and grand opening

When we first discovered Shinola Bicycles, it seemed like a cool idea: Grow US bicycle manufacturing and bring new industry to Detroit. But after getting to see them up close and meet the people behind the brand, we’re more excited for them than ever.

We were invited to their store grand opening, which also doubles as the bicycle assembly and shipping facility, an R&D prototyping room and sales center. Besides seeing the bikes, we chatted up Richard Schwinn, the man behind Waterford Cycles, which builds all of the frames and forks, and Sky Yaeger, the design leader, who’s worked with Bianchi and started Swobo’s bicycle line, and many others involved in bringing new life to the Motor City.

Shinola also makes watches, which we photo’d being hand assembled. Tick through for the full tour and a detailed look at what makes these bikes special…