Ellsworth-y
It's Thursday all ready, isn't it. I tell you, this week is flying by. I meant to have this up yesterday, but, alas, it was not to be.
Anyway, backing up a few days, Tuesday I ventured North to Vancouver, WA, to visit the Ellsworth factory, meet the folks there, talk to Tony and--most importantly--ride. It was a busy day.
Now, this wasn't the first time that I had visited a factory before. I met the nice folks at Fox Racing Shox a couple of years ago, and I've met with the good people behind Rolf Prima Wheels. But, this was a frame building operation, so I was interested to see what Ellsworth did and what they farmed out. Turns out, they do pretty much everything but the anodizing in house.
The photo above doesn't show all of the factory, but quite a bit of it. Here they bend the tubes (the tubes arrive externally and internally tapered) to the desired shapes; make the gussets; machine the head tubes; machine the linkages; make the swing arms; acid dip, anneal and heat treat the welded frames prior to anodizing them; and weld the frames.
Here, Troy is showing a before and after tube. This tube is shaped from round to oval. After they've made it oval, it'll be bent into a more interesting shape. This is a two step process.For each shape and size of tube, they have a two-piece steel form that attaches to the press behind Troy. Once the tube is in place, they squeeze it with around 2300psi. This is done before heat treating the tube, naturally.
All of the frames--once welded up--get placed in this holder for acid dipping and heat treating.This holder helps keep the frames aligned during the heat treating. After this is done, all of the frames are checked for alignment using a single swing arm. The swing arms are checked out on their own using the jig shown below.
This is a very good thing for two reasons: 1) every swing arm will work on every frame. If they aligned the frame with the swing arm, one or both of them could be off and if you needed a replacement swing arm, it might not be aligned with the frame. 2) If you notice during the final build that something isn't quite right, it's easier to track down the culprit. Seeing this made the engineer in me very happy.
Overall, in talking to Troy and David--thanks for showing me around, guys--I got an overall feeling of craftsmanship. These guys are passionate about making the best frame that they can. If something goes wrong with a frame, they want to know why so it doesn't happen again.
Ellsworth builds about 2000 frames each year. That puts them in no man's land--bigger than a custom frame shop, but much smaller than the big bike houses. They are a boutique brand. You'll end up paying more for your frame, but you'll know that your frame was checked our prior to shipping out. They don't check a random number of frames, they check them all. If they were bigger, they couldn't do that.
Tony, Troy and David, thanks for showing me around. It was a pleasure to meet you and see how the bikes are made.
Oh, and the ride was a blast as well.

