The technological process for producing a wooden bicycle frame is quite complex. The first step is the purchase of the material – raw plank boards. Wood types vary and allow a variety of combinations and processes to yield unique patterns, as desired by the client. The commonly used essence is ash wood, which offers an optimal ratio between weight, strength and elasticity. This is combined with a range of other wood types with different structural and esthetic qualities (walnut, oak, mahogany, wenge, padauk, american walnut). The price of the wood varies between 700 euro / m3 (ash) and 4000 euro m / m3 (padauk). The wood is then prepared for processing: the right material is chosen depending on structure and the material goes through precise cutting, lamination, surface finish, milling, etc.
After the frame is ready, next is to attach the metal inserts: the pipe supporting the rod saddle, the pipe supporting the bottom bracket tube, the pipe in which the front fork is mounted etc. Some of these metal pieces are made in our own workshop and others are ordered from dedicated workshops.
The manufacturing process continues with the verification of the entire wood assembly: the bike is mounted in a special metal “jig” which helps provide the last adjustments to the overall assembly (checking the angles, matching and aligning the wheels and the frame).
Next is the finishing: wooden parts are ready to be treated with epoxy and UV resistant coatings similar to those used in the finishing of wood craft. This phase involves sanding and the application of wood coatings 3-5 times for a high quality result. The work is extremely time consuming due to the long drying time and curing of various components and because all task, even though repetitive, need to be performed with the outmost care and attention. The last layers actually seal the wood (both internally and externally) covering all its pores and prolonging its life and use.
The last phase before shipping is the trip to one of our bike service specialized partners. The frame is equipped with all parts and accessories (front fork, handlebars, exchange, brakes, brake shoes, wheels, pedals, hubs, saddle, etc.) Final adjustments and checks are then done, which marks the successful completion of a cycle of about 3-4 months of work.