NAHBS: Great Lug Work
Atmo’s Newvex lugs in a naked frame.
Sachs’ lack of overflow silver is part and parcel of why he is considered the best in the biz.
The Newvex BB.
Front view of the same frame.
The one-color paint is rather lackluster, but Mark DiNucci’s lug work is second to none.
Bruce Gordon’s Custom Ti/Carbon Bike
Bruce Gordon is a codger. He’s not one to suffer fools. His swipes at the industry with his SOPWAMTOS (Society of People Who Actually Make Their Own Shit) awards have inspired laughs as well as ruffled feathers. But that’s the kind of guy Bruce is. He does what he does because it makes sense to him.
That crusty exterior of his has been known, on occasion, to make him a touch less marketable. I’ve been talking to the guy for more than 10 years and his skeptical, cynical edge has been tough to chip away at. That said, I’ve made some progress and these days he talks to me honestly about what he enjoys doing.
Here’s the thing about his work. He knows it’s not just good, but great. And when people don’t get just how good it is, he can seem a touch irascible. When you’re as inventive as Bruce is, it’s fair to think your work should be appreciated.
For the 2010 San Diego Custom Bicycle Show, Bruce built a special bike. He has made a number of bikes and components over the years that have used titanium to great effect. The bike he showed at this year’s show went to truly unusual lengths.
The bike looked very familiar due to the fact that the lug lines and windows recall Bruce’s previous work. At first glance, the bike definitely looks like a Bruce Gordon. And then there’s fact that the bike is huge; Bruce makes all bikes he’s not sure he’ll sell at market rate in his size—61cm—just to be assured the bike will get ridden. But the fact that all this bike’s tubes were carbon fiber made it quite unusual.
Carbon tubes have been bonded to aluminum lugs for a generation. It’s been so done, it isn’t done anymore, generally speaking. And carbon tubes have been bonded to titanium lugs on occasion. One of the most notable examples was the limited edition Specialized Epic that featured titanium lugs. That Specialized has a familial relationship to this bike as it turns out.
The carbon fiber bottom bracket lug show above came from Serotta. In order to create this bike, Bruce—who has zero experience crafting tubes from carbon fiber—had to partner with someone. In the strictest sense this bike is a collaboration, rather than just a Bruce Gordon creation. Bruce worked with Mike Lopez, who runs Serotta’s composites facility in San Diego. Lopez has an interesting history in the industry. For more than 30years Lopez has been involved in bicycles that use carbon fiber. He has worked for Serotta, Reynolds and way back when, Specialized. He was involved in the carbon fiber Epics. As a matter of fact, the jig on which this bike was assembled used to be used for Epics.
Bruce says he likes the look of a bike with classic design elements and modern materials. In achieving his aesthetic of a touring bike with fenders he, Lopez and a few other people invested more than two months in the bike. Bruce says he has no idea what he would charge for the bike but is committed to making one more—for Lopez.
Bruce had to enlist the help of another guy as well. Salsa founder Ross Schafer did the CAD work that resulted in the lugs that were machined to Bruce’s specs from bar stock. Chris Hayes welded those pieces into actual lugs. On details like the rake of the forks, Bruce had to show Lopez just how to shape the blades both in taper and curve.
Jason Lilly shaped the fenders, shown below. The paint, which turned out to be more challenging than expected, was applied by painter-to-the-stars, Joe Bell.
Sean Walling of Soulcraft, Mark Norstadt of Paragon Machine Works and Doug White of White Industries lent advice on machining the many parts involved in the frame, including the special dropouts and fork crown. Basically, nothing in the frame is off-the-shelf.
I saw a great many very fine bicycles at the San Diego show. I can’t think of a single one that showed as much individuality, practicality and beauty balanced as elegantly as this bike. Unique is a word that is used much too often. This is one of those times when it is absolutely appropriate. At least, until the other one is built.
Sampson Sports s5 Pedals
My first experience with Sampson products came back in 1987 when a coworker at the bike shop I worked at bought a Centurion Ironman spec’d with Sampson pedals. For those of you who don’t recall these pedals, they featured an unusual L-shaped cleat that wrapped around the back of the pedal. They featured a unique clutch that held the pedal in place after you clipped out so that upon clipping in again it was in (hopefully) exactly the right position to clip in without fumbling around with your shoes.
The cleats were very difficult to walk in and broke. A lot. I wasn’t exactly impressed.
A few years went by and I received a test bike from Sampson. It was made from Reynolds 853 steel. For construction, Eric Sampson sought out Reynolds’ famous frame shop in Nottingham, England. This was the frame shop where all the Ti-Raleigh frames were built, a shop with as much history as there is to be found in the bike industry. The bike included a few different Sampson components, including cranks.
The bike was one of my favorites of the quartet that I reviewed. My opinion of Sampson changed dramatically.
Since then, I’ve reviewed two more Sampson bikes. Each time, he has done something essentially unknown among his competitors: He calls me and asks me what could be better. Invariably, I get another call a few months later in which he tells me about what changes he was able to make to respond to my suggestions.
I confess, during these calls I rock back in forth in my chair, grinning at my obscene power. Weekly calls of this sort could give me an ego transportable only by 18-wheeler.
So a couple of weeks ago I received a pair of the new s5 pedals. They feature steel spindles, a lightweight alloy body, a 62mm-wide cleat platform, three cartridge bearings and a cam-graduated hinge to make entry easier. The s6 pedals feature a titanium spindle.
Sampson claims a weight of 121g per pedal. My test pedals weighed exactly 121g each (the titanium model has a claimed weight of only 99g per pedal). I was so dumbfounded, I weighed them a second time. I can’t recall the last time a weight was accurate to the gram. Eric says he weighed at least eight pairs himself just to make sure the weight was dead-on.
Eric says that unlike most competitors’ pedals the contact plate on the s5 is replaceable to allow you to keep the look of the pedals new. The spring tension is also very adjustable thanks to a 20-position indexed Allen bolt. The cleats mount via a standard three-hole mounting pattern.
I’ve been a Speedplay X user for more than 10 years. While I have some other pedals at my disposal, Speedplays have been my pedals of choice. Non-Speedplay users tend to be critical of the system, pointing out how shoes will rock side-to-side when the cleats are worn. I tend to replace my cleats pretty frequently and never have any complaints about rocking or the amount of float when using them. It feels perfectly natural.
Okay, so that said, the Sampson’s are striking for their secure feeling. My cleats featured no float, which added to the ultra-positive power transfer. Entry and release is easy enough. I’ve set the release tension pretty low; thrashers afraid of unwanted release can increase tension dramatically.
Suggested retail for the s5 is $139, while the s6 goes for $239. Initially, they will be available in red and white. My test pedals are pre-production; they should be available in black in June.
I’m not sure there’s much more to say about a pair of pedals other than they are light, easy to get into and release and, best of all, provide a secure platform. By comparison both the Dura-Ace 7800 and 7810 pedals—while good pedals—they are heavier than the Sampsons, don’t feel quite as secure and are more expensive. Same for the Look Keo Sprint.
For years I wrote that Sampson products were a terrific value because they typically offered 85 percent of the performance of the top-drawer stuff for 50 percent of the cost. Those days are gone. He said he wants to compete head-to-head with companies like Shimano. After riding these pedals, there’s no denying that they are a great alternative to Shimano and Look.
Builder Interview: Dave Kirk, Part I
RKP: Where are you based?
DK: I work from my home shop in Bozeman Montana. Bozeman is a small university and ski town of about 30,000 people located in southwest Montana about 90 miles north of Yellowstone Park. Bozeman is in a valley surrounded by mountains on every side and it’s the ‘big city’ in the area. When you leave town you have really left town and you can ride for miles and see no one at all. I like my solitude and I love Bozeman.
RKP: Is that where you grew up?
DK: No. I grew up in a wonderful small town in central New York State – Rome NY. The riding in the area is world class and for the most part no one knows about it. Every other road is called “farm to market’ road and they are all 1½ lanes wide and just meander through the countryside and farmland up and over 20% super steep climbs……… It’s like Belgium but with out cobbles and I speak the language. I lived in Rome until a few days after high school graduation and then a good friend and I took a road trip to Florida to meet girls. I ended up moving to Florida and went to school half-heartedly but raced BMX with gusto. The southeast was the place to be in the early 80’s for BMX.
RKP: What’s the riding like there (where you live now)?
DK: The riding around Bozeman is much different from Rome where I grew up. Instead of short uber-steep climbs Bozeman has very long alpine type climbs that go up to about 8000’. It’s easy to find climbs of 10 miles or more and it takes a much different mindset. You certainly don’t just stand up and hammer over them. Many of the roads here leave town and get narrow and rough and then turn to dirt. These are my favorite roads to ride. I like the feeling of being way out there and away from everything and slogging over the rough loose surface. I could do that all day. I ride alone most of the time. No wonder why I guess.
RKP: How long have you been building?
DK: I started working as a full time professional framebuilder in 1989 at Serotta in Saratoga Springs, NY. With the exception of one summer working as a water well driller and a few winters working as a snowboard school supervisor it’s all I’ve done since 1989.
RKP: How did you get your start?
DK: I was living in Rome NY and working at a bike shop in the area called “Dick Sonne’s Ski, Hike and Bike” when I got a call from a guy at Serotta. They knew of me through my racing and wrenching and needed more warm bodies in the building. I went and interviewed and Serotta at that time was in a barn with the paint booth being in the chicken coop. It wasn’t very impressive but I really wanted to work there. They offered me a job as a mechanic and I took it. About a week before I was to start I got a call from the same guy and he told me there was going to be a delay and could I start in two weeks. Sure, no problem. Two weeks turned into 6, which turned into 12, and I finally gave up. I started working at a small bike shop close to my home called Schuss Ski and Bike and about 2 years after that first call from Serotta I got another call. This time it was Ben Serotta himself and he told me he had just found out how I was treated first time around and apologized. He then told me they were looking for help in the frame shop and asked if I wanted to interview. The night before the interview I was out riding in the woods and stumbled on a bee’s nest and my hands were badly stung. They got so huge that I could barely drive. I went to the interview and kept my hands out of sight and it was all going well. I was then asked to go into the shop and use a few tools to they could judge my hand skills. I flopped my hands onto the desk and told them I didn’t think I could do that today. Everyone moved back a steep when they saw my freakish hands. They ended up offering me the job anyway and I started work as a framebuilder on October 2nd, 1989.
RKP: Is building your day job? If not, what else do you do?
DK: I am a full time professional framebuilder and it is all I do.
RKP: Have you held other positions in the industry?
DK: I started working as a kid in bike retail and as a mechanic. I’ve raced professional BMX and mountain bike and some road. I worked at Serotta for 10 years and ended up being the one man R&D department and was responsible for all new products, the tooling to produce them, as well and personally building the bulk of the bikes to be used by the professional teams Serotta sponsored at the time. I then moved to Montana and worked with Carl Strong as general shop help and he and I eventually formed a production company to produce Strong Frames as well and all the steel Ibis’. I then struck out on my own and formed Kirk Frameworks in June of 2003.
RKP: Do you ever work in a material other than steel?
DK: Over the past 21 years I’ve worked with most every popular frame material (and a few not so popular) but I now work exclusively in steel. I like working with and riding steel better than any other material. It speaks to me in everyway.
RKP: Who makes the tubing and lugs you like to use?
DK: I work with mostly Reynolds tubes but also use a bit of True Temper. The good folks at Reynolds make proprietary tubes just for me and they are vital to my getting the ride just the way I think it should be. For lugs I like Sachs and Llewellyn. I’m just introducing some dropouts of my own design and have plans in the works to expand my offerings. My job at Serotta was product design intensive and I missed the challenge. That combined with being unsatisfied by the parts available to the professional builder I decided I needed to design and make my own.
RKP: Tell us about the jig you use.
DK: I use Anvil frame and fork jigs. All my other tooling (bending, braze-ons, lug holders, etc.) I’ve designed and made myself. I love designing and making tools. It’s a lost art.
RKP: What sort of cutting and shaping of lugs do you like to perform? Does it vary from bike to bike or are there stylistic elements people can find running through all your bikes?
DK: I favor simple, purposeful and straightforward designs. While I like and admire frilly and baroque designs they aren’t what I like to do. My bikes are all a bit different but there is a common theme to the look. While I offer lugged bikes I also offer and love building fillet brazed bikes. I think the beauty of a properly proportioned fillet joint has few rivals.
RKP: When fitting a customer for a bike, how do you usually work? How often is it in person?
DK: Being in the middle of nowhere I get only about 3 people a year visiting for fittings. I welcome all to visit but understand that isn’t very often possible. I design the bike based on the customer’s body dimensions, and how the bike is to be used. I double check the design by getting the contact points of their current bikes as well as feedback on how they feel these bikes fit, ride and handle. I will sometimes ask for photos of the rider on the bike just to see how they tend to hold themselves. All of this info, along with the answers to an extensive questionnaire I send out, gives me a very full image of the rider and their needs.
RKP: Let’s talk about geometry: Would you say your all your bikes have a consistent ride that is your signature, or do you vary your geometry based on the customer’s preferences and needs?
DK: Some of both. I think all of my bikes ride like a ‘Kirk’ regardless of what the intended end use is. They all have that same Kirk DNA. I feel the most important thing is to be sure that the bike will fit and handle well considering how and where it is to be used. From there the numbers are picked to give a certain ride in those conditions. I like my bikes to have enough stability to give confidence and at the same time have a lot of ‘snap’ and jump’ to give the bike spring and life. This is done by not only getting the geometry right but also picking the proper tubes for the rider.
I feel very strongly about forks and every Kirk frame goes out the door with it’s made to match Kirk fork. I do not offer off the shelf forks. Each one is designed and built to match the frame’s geometry and the desired ride qualities. It’s next to impossible to get the handling and alignment just right when ½ of the design was done by someone else who knows nothing about the needs to the rider. The frame and fork need to be designed together to work properly together and to give the proper handling and ride.
RKP: Who does your paint?
DK: The one and only Joe Bell paints everything I build.
RKP: How long is the wait for new customers?
As of January 2010 my wait is about 11 months from receipt of deposit to delivery.
RKP: What’s your pricing like?
DK: I offer two different levels of build. My standard lugged frameset sells for $2900 and a fillet brazed frameset is $3000. I also offer the JK Series names after my father John Kirk. They differ from my standard frames in that they use a bespoke blend of lightweight tubes (953, S3 and special tubes Reynolds makes for the JK series). I offer the JK Special road frameset for $3600 and the JK Cross frameset for $3700. All these prices include a single color Joe Bell Signature paint job. If the client wants more elaborate paint that is done at an upcharge.
RKP: What keeps the work fresh for you, gets you up in the morning (or out in the evening) and excited to build?
DK: I work a pretty standard work schedule and I do my best to never work too late or start too early and I never ever work weekends. I do my best work when I am fresh and rested and wanting more. This is hard to do sometimes because I really like the work itself. I love going over the tube bin and selecting the tubes to be used in a given bike and laying them all out for inspection and letting the process happen. It’s this process that keeps me excited and motivated. I’ve built thousands of bikes over the past 21 years and it’s always been the process that motivates me.
RKP: You’re part of the Framebuilder’s Collective. What was the motivation to get involved in an association devoted to what can be a pretty solitary craft?
DK: Can you say “herding cats?” I am one of the eight founding members of TFC and I originally became interested in forming a group after spending so many hours in the shop talking with Carl Strong. We were frustrated by the lack of resources for the new builder and by seeing so many talented and skilled builders hang their shingle, build some very nice bikes and then go out of business because they didn’t know how the whole business thing worked. And at the same time we saw plenty of other hobby builders hang their shingle when they were not at all ready to build bikes for paying customers. There is just no professional standard for building or business practices in this industry and each bad business transaction a customer has, and every poorly constructed handbuilt frame out there reflects poorly on the whole group of us professional builders. We want to do what we can to promote professional building and business practices and to further promote the image of the handbuilt frame.
RKP: What’s your life away from building like? Are you racing or do you have outside interests?
DK: I love to be outside and moving quickly. I ride my bike as much as possible in the mountains surrounding Bozeman, I snowboard and cross country ski and I race autocross. The autocross (also known as SCCA Solo) gives me that competitive rush I seem to need in a big way. I’m proud to say that I‘m two time state champion racing a Birkin S3 in the modified class and this year I’ll be moving into a 2005 Lotus Elise and trying to up my game. I like the process of learning to set up and drive the car at it’s limits. It’s always the process. I also love spending time with my wife Karin hanging out in the greenhouse or the garden, watching the plants grow. There’s not much better in life than getting back from a dirt road ride, cracking open a good dark beer and hanging out in the garden watching our four cats play and chase each other around. A good thing in every way.
Images pilfered liberally from Kirk Frameowrks
