Build Process

Every KirkLee Custom bicycle starts by contacting us and filling out the KirkLee Fit Sheet. Using the fit sheet combined with your existing bike geometry and ride preferences we work with you on finalizing your KirkLee’s geometry. We’ll send you 2D and 3D drawings of your custom carbon bicycle that you sign off on before we begin building.

Once the design is finalized, tubes are hand selected based on rider preferences and loaded into miter fixtures to ensure an optimum fit. H₂O bosses are drilled with a high or low mount option and tubes are prepped for bonding.

Custom templates are designed, drawn and cut for each custom carbon frame. Aerospace grade bonding agents increase frame strength and lock the frame in place to aid in the application of unidirectional carbon templates. Each tube intersection is hand wrapped with unidirectional carbon fiber with the number of plies and orientation dependant on rider size, weight, and strength along with the ultimate intention of the bike.

After the curing process, final prep begins with sanding the bike to a near perfect finish. This is where the magic happens, but sadly we can’t reveal all of our secrets.

Carbon cable stops are installed using our MTEC bonding technique to give both a chemical and mechanical bond. The bottom bracket guide holes are drilled and all cable routing holes are installed. The bottom bracket is faced and chased along with facing the head tubes. This allows a perfect fitting bottom bracket and head set on each carbon frame.

Final sanding takes place and the bike is ready for paint. To carry through with our philosophy to build the best custom bikes possible, all KirkLee logo’s, names and lettering are painted on. The only exceptions are when we achieve a brushed metal look.

Once your KirkLee returns from the paint booth, it is prepared for final delivery. Each KirkLee Custom is carefully packed and ready to go once delivered. You can be rest assured that your custom bicycle will provide many years of enjoyment built from the hands of KirkLee.