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Frame and fork manufacturing
Frames are constructed from galvanised alloy tube to protect against corrosion. Tubes are precision cut and mitred to ready for welding. Our skilled technicians assemble and TIG weld the frames together in jigs. Bottom brackets are threaded, ready to connect the cranckset.
Welded frames are heat treated and air dried to improve strength.
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Painting
Frames are cleaned and inspected before the painting process begins. Oil and dirt are removed by immersing the frame into a non-hazardous chemical bath.
Automatic disc painting booths provide a comprehensive colour coat. Painted frames are cured in an industrial oven.
Quality control inspectors check the painted frames to ensure they comply to the colour and finish specification.
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Applying labels
Skilled technicians apply the brand and product labels to the frames. We have mastered the technique of transferring a print image onto the frame.
Water transfer decals are carefully applied. Frames are placed in an oven to set the decals. A clear coat is painted all over the frames before low baking in an oven.
Lower cost adhesive labels can be substituted instead of water transfer decals, especially when small production runs are made for custom models.
Quality control inspectors complete a comprehensive check of the frames before they move to the next stage of assembly.
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Wheel Assembly
Spoked wheels are hand laced by skilled technicians. Laced wheels are placed in automated machines to tighten spokes to a specific torque. Alignment machines true the wheels to industry standards. Tube and tyre combinations are fitted and filled with air. Other components are fitted to the wheel hub before moving to the next stage of production.
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Final Assembly
Frames and wheels arrive separately by conveyer. They converge with parts delivered from stored inventory in the warehouse. Chain wheels, gears, brakes, handlebars, seats and other components are added as the frame moves along the assembly line. Each station checks their components and matches them to the bill of materials before assembly.
Quality control inspectors make their final assessment before the completed cycles are sent for packaging.
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Packaging
Completed bicycles are partially disassembled, wrapped and secured for packaging. Export grade cartons are used to protect the bicycle and other components, operating manual and warranty card. Contents and address labels are adhered to both sides and the ends of the carton. Flaps are sealed with staples. Safety bands are used to secure the carton.
Packaged bicycles are palletised, ready for dispatch to local and export markets.