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Current Lead Times: Simple-Custom Framesets: 1 week. Full Custom Bikes: 7 weeks.

U.S. Built Custom Bicycles in Titanium and Titanium-Carbon Mix

Crossing Categories

Expat 29s

In the beginning (1997) we were  known as builders of custom road and mountain bikes, and certainly of the more than 25,000 frames we’ve turned out, many of them fit neatly into one of these two categories. But as we’ve gone along, we’ve expanded our line to include more models than any other custom builder. Today we build cyclocross race and adventure bikes, urban commuters, track  bikes and tandems.

Another thing that has happened is that the basic constraints of traditional categories have broken down, so that today, even though we are still building traditional road and mountain bikes, a very high percentage of our work is on bikes that cross categories or even combine them. Cyclocross race bikes that convert to bad weather commuters are common. Road bikes that convert easily for touring. Monster cross machines.

What our riders are beginning to understand is that a custom bike can be designed to serve multiple purposes simply by incorporating some features not commonly available on production bikes. Often, when they are thinking of buying two bikes for two different aspects of their cycling life, we can build them just one.

Categorization can be a good way to understand a bike’s basic functionality, but it can also be a constraint, and when you’re in the business of building dream bikes, no one wants to be constrained. That’s why we do what we do.

Bike Builders

A busy production floor

First there is Skip who opens the shop early. He uses the pre-dawn to make his rounds, cleaning and lubing all the machines on the shop floor. He spends all his days maintaining our tools and building new fixtures. Skip is the bike builder who builds no bikes.

Next through the door is Mike or Chad. Mike is our lead machinist. He does the CAD drawings of frames that guide us as we move from tube set to finished frame. Chad hits the finishing department and tries to work his way through whatever didn’t get done the day before. He fires up the drills and fills the air with the whirring noise of things being built.

Jennifer and Rob arrive. Inventories get sifted through. Parts orders get readied. Rob sorts a stack of folders, orders for new bikes with designs from Dan or Neil already done. He evaluates their work, makes notes for changes, improvements.

The welders, Stef, Tim and Yoshi, show up. They wheel the freshly prepped tubes from machining into their own department and assemble them in the frame jigs. Gas lines get fitted to the jigs. Oxygen gets purged. Joints get tacked and then checked for alignment.

Painters come, too, Staci and Jordan. They pull primed frames from the drying booth and begin sanding out imperfections or begin masking for top coats.

In the office, the blinds slide noisily aside and Karl sits down at his desk, cracks his email to see what’s come in over night, questions from shops from all over the world. Orders get pulled off the fax machine. The coffeemaker stirs to life.

Throughout the morning, the rest of the crew rolls in, Matt and Mary, Dan and Nick and Lloyd, Seth and Lauren, Sutts. The whirring sounds rise and fall. Compressors fire and shut off, and frame-by-frame the boxes fill up in shipping.

Wasting No Time

Long wooden crates at the garage door entrance

Well, we made it through the holiday rush, getting out all those bikes that had been promised as gifts, and it was nice to get a few days off with family and friends to over-eat, dream about bike riding and then over-eat some more.

Sure enough, a truck rolled up first thing this morning with three boxes of raw Ti tubing to be crafted into the New Year’s custom bikes. Nick and Sutts loaded the first one onto the dolly and wheeled it off to machining.

Lathes and mills spun to life. The compressor to the paint booth cycled on and off. The coffee maker bubbled and spluttered.

We gathered briefly by Nick’s computer in shipping to watch the end of the World Cup cyclocross from Belgium (SPOILER ALERT: Nys won, again), before catching up on the orders sent in over the weekend, updating status on bikes in process and chatting idly about the impending winter storm.

This is the thing about doing something you love to do. It’s nice to take a break, but it’s also nice to get back to work, wasting no time, while riders here, there and everywhere dream about their new bike.

The Weight of Experience

filing cabinets labelled 2007, 2007 cont.

We have every order that’s ever been phoned, faxed or emailed to us here at Seven. When a rider orders a second or third or eighth bike from us, we pull their archived orders and combine them so we can factor everything we know into the new build. Building one bike at a time, this one of the ways experience accrues.

We keep all the orders in manilla folders, one for each bike, in a long line of file cabinets, alphabetized and labeled by year. Each order is mirrored in our database, but we keep the paper because it helps us capture every detail and have hard back up for power outages or digital meltdowns.

There are 30 cabinets spanning our history. Pull the orders out and you’d get a pile 240 feet high. Altogether, they weigh roughly 5,000 lbs (2275kg). More than two tons.

This is the weight of our experience. We don’t know a ton about custom bike building. We know two tons.