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Citybike Commuting & Touring - November 2011

Designed for extreme low maintenance and ease of use with the aim of removing barriers for those who don't ride bikes. >3000 miles covered to date.

Frame

6082-T6 Alloy externally butted w.split RH dropout

Internal cable routing and wiring

Integrated rear lights

 

build

Shimano Alfine components w.11speed internal gear hub

Shimano Alfine wheelset inc. 3W front dynamo

Gates belt drive

Brookes leather saddle

 

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Tandem Mk5 29er FS built for the Sea Otter Classic - April 2018

Built for the 2018 Sea Otter Classic tandem XC race in Monterey, CA. 100mm front and rear travel with virtual pivot linkage rear suspension and modern standards including a 1.5" tapered headtube, 92mm press-fit rear BB and boost rear axle. 

Frame

7005 alloy mainframe, 6061-T6 alloy rear triangle

Internal cable routing

6061 machined linkages with double-row lower bearings

142mm x 12mm Boost rear axle spacing

100mm front and rear travel

Build

Shimano XTR 1x11 groupset (timing chain on driveside)

Modified Maverick American DUC32 fork

Hope Technology rear hub & brakes with twin front rotors

Custom front hub for twin rotors

Rock Shox Reverb dropper posts

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Adaptive Rowing Handle British Paralympic Adaptive Rowing Team - July 2014

Designed and fabricated for British Rowing Paralympic athlete Oliver Hester. His hand was laser scanned (live and using a plaster cast) and a handle was created in CAD. An initial 3D printed (FDM) prototype was tested for fit & function and following some iterations a mould was created from the FDM plug and a PU rubber part was produced with an aluminium core.

He used this handle throughout the 2014 season culminating in winning gold medal at the World Rowing Cup in Aiguebelette, France and the World Rowing Championships in Korea in the same year.

 

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This project was the basis of a PhD research thesis and involved expanding the science behind the prescription of prosthetic running legs. It examined the dynamic action of the foot spring when combined with the amputee as a system. During this project a foot was instrumented with portable data acquisition apparatus to allow factors such as ground contact position, runner mass, ground contact force and all aspects of stride timing but with freedom away from a gait laboratory. This research was carried out in association with Bournemouth University, Ossur prosthetics and MSR Dataloggers.

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XC FS Race bike Built for the XTerra World Championships in Maui, HI - September 2008

Built for elite athlete Pete Hawkins for the 2008 XTerra World Championships in Maui, HI. The frame uses flat plate carbon fibre / aluminium sandwich chainstays to provide vertical rear wheel compliance with high lateral stiffness, and a pultruded integrated seatpost bonded in place. 

The bike helped Pete to take the gold medal and become World Champion.

Frame

6082-T6 alloy mainframe with pultruded carbon seatpost

Carbon / aluminium / carbon sandwich chainstays

Roll-wrapped UD carbon seatstays

135mm rear axle spacing

Manually machined rocker links

build

Shimano XTR 3x9 groupset & brakes

Maverick American DUC32 fork

Hope Technology Pro2 hubs & Mavic rims

Custom built seat clamp

 

 

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CNC Router Built to machine moulds for composite frames and components - 2011

This router was designed and built to machine epoxy tooling board in a large enough format to produce a composite bicycle frame mould. Stepper motors with recirculating ballscrews and limit switches on all three axes. All electronic stepper drivers, spindle relay and power supply are integrated into the frame with active forced-air cooling. It uses a 1kW Kress spindle motor with up to 10mm cutter shank capacity using collets.

 

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Tandem Mk4 FS 29er built as a wedding present - September 2013

Built as a wedding present for a couple of mountain bike fans using the most modern standards of the time and the best tandem-specific components available. 29" wheels, 100mm front and rear suspension travel with a virtual pivot linkage at the rear. 150mm x 12mm rear axle spacing.

Frame

6082-T6 alloy manually externally butted

6082-T6 alloy CNC machined links

Internal cable routing

9.25lb frame weight

build

Shimano XT 3x9 groupset with carbon tandem cranks

Maverick American DUC32 fork

Hope Pro2 rear hub & Maverick American front hub

Stans Notubes rims

Rock Shox Monarch rear shock

 

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Composite 29er FS Race Frame - Work-in-progress

Still a work-in-progress, this frame is a composite moulded structure utilising live chainstays for vertical compliance but high lateral stiffness, an integrated seatpost and carbon fibre suspension link. Moulds have been machined and are being prepared ready for initial moulding trials.

Frame

UD high modulus carbon fibre prepreg fabric layered on to a foam core / silicon bladder

29" wheels, 2.25" max tyre size

142x12 Boost rear axle

Direct mount front derailleur

Bonded cups used for headtube and BB shell

production process

This frame is to be made using machined epoxy tooling board moulds and a custom formed silicon bladder over a cast foam core (which is later removed). Chainstays are moulded with the mainframe. The seat stays are moulded separately and joined to the chainstays by overmoulding the form of the carbon dropouts (compression moulding). 

This frame is designed for a 2x10 Shimano drivetrain.

 

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Bella hardtail 26" lightweight race frame - April 2010

Frame

6082-T6 alloy frame with roll-wrapped carbon seattube

Manually externally butted main tubes

16Ga. chainstays, 18Ga. seatstays

Internal cable routing with integrated guides

2.6lb frame weight

build

Shimano Deore 3x9 groupset

Headshox 70mm fork

Hope Technology Pro2 hubs & Mavic rims

Hope Technology 'Breast Cancer' edition brakes