Just prior to PressCamp, Reynolds invited us to tour their US headquarters, where all of their wheels are designed and developed. It’s also where a fair number of complete wheels are hand built and tested, prototypes and production pieces are tortured and all of their top-end RZR wheels are made.
Reynolds Cycling is owned by McLean Fogg, a large manufacturing company that makes automotive parts and industrial power line equipment. They also used to make carbon tubes and materials for frames (including the OCLV frame tubes and Rolf carbon wheels used by the Postal team), windsurfing booms, Halliburton luggage and their own bicycle cockpit parts.
Unfortunately, the non-automotive parts lost money. Between 2005 and 2007, new folks came in with the goal of “fix it, sell it or close it”, including current CFO Mike Dufner. What they figured out was they could have a competitive advantage in wheels. By 2008, bicycle wheels were the sole focus, all using Paul Lew’s designs, patents and processes.
All design and development is done in-house in Sandy, UT, just outside SLC. They have a duplicate development and testing facility in Hangzhou, China, near their own manufacturing plant. They also produce rims for other brands, but generally reserve their best tech for Reynolds products.
They control the process from start to finish. They buy the carbon from a US source, then ship it to China. This ensures better quality control and eliminates middle men in the supply chain that could insert inferior grade products. They develop their own resins, and as of about a year and a half ago, they make their own molds here, too.
Roll on for a full tour…