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Copyright 2008: Intrepid Equipment LLC
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Manufacturing Process Intrepid Handcycles start with the highest quality materials. We use 4130N aerospace seamless Chromoly tubing. After you have placed your order we select the correct tubes, check them for defects and check the order before we begin to cut. First we cut all our tubing to approximate length we use precision machines for coping and mitering the tubes and cutting the flat plate. There are 28 cutting operations for the standard frame alone. After cutting, the tubes are thoroughly deburred and washed. Then they are fitted into welding jig and tack welded. On the main frame there are 23 places that need to be tacked and then welded. Before welding, the geometry of the frame is carefully checked against our jig. At this stage the frame can be tweaked if necessary to obtain precise geometry. Then the frame is careful and slowly TIG welded. Tig welding handcycle frames is an art. The metal expands and contracts due to heating and cooling as it is welded. This can cause the frame to distort. The welders job is therefore not only to create strong good looking welds, it is also to weld the frame in a sequence that balances out any heat related distortion generated from expansion and contraction. This is a very skillful job and is the key to a beautifully crafted frame. This process is repeated for each of the components of the handcycle.
In all there are 72 pieces to be precision cut and welded. This compares to 10-15 for a normal bicycle frame. During this process the seat back is moulded, trimmed, and drilled, and prepared for painting. Following welding all of the telescoping pieces are slotted including the lower fork, the seat support stays the, triangulating adjuster, and the crank bracket. Pieces including the lower fork are then reamed for a precise internal diameter. The upper fork is also drilled to accommodate the caliper brake mount boss which is welded into place. The derailleur hanger is tapped, and the disk brake mount holes are drilled, and the alignment of each is checked. Finally the front wheel alignment is checked and the dropouts are ground. The parts are then all debured and washed again before they are lightly sanded and masked ready for painting. Two coats of filler primer are applied. This forms the base for the color coat. The primer is checked and sanded as needed. A coat of primer sealer is applied to enhance the bond between the primer and the base coat. Then two coats of color base coat are applied. This is then allowed to air dry over night. The following day the decals and logos are applied to the frame followed by 2 coats of urethane clear coat. This is then placed in a baking oven and allowed to cure for 2 hours, and then it is allowed to air cure for an additional 12 hours before we begin assembly. While the paint is curing we cut and sew all of the upholstery on the handcycle including the footrest straps, seat back cushion and seat base cushions. During this time we also machine all of the aluminum components for the handcycle including all six pivots, and the insert lugs that establish the camber of the rear wheels. Then when the paint has finished curing and we remove all the masking so that we can begin the assembly phase. Assembly begins with pressing in the headset, and follows by attaching all of the other bicycle components, clamps and fitting all the frame parts together. Extreme care is taken during this phase to avoid damaging the paint. The cables and chain are all routed and adjusted. The brakes and gears are tested. The last step of the assembly phase is to build, true, and attach the wheels to the handcycle. Finally we test ride every handcycle to make sure that everything is working properly and any last minute adjustments are made. Once we are sure that the handcycle is working properly we pack them up and ship them to our customers. When you ride your intrepid handcycle, remember, it is a skillfully crafted precision machine that was built to last. |
