Custom Built Bicycle Process

Hand Built Bikes, Lugged and Brazed

Custom Built Bicycle Process

Our process starts with a conversation with you about goals and aspirations for a custom bike. We discuss the pros and cons of any of your current rides, what type of riding you plan to do on your new O’Leary bike. And we will identify any postural issues or problems with cycling we can address in the new frame. Then we take important body measurements and begin designing the bike on Bike CAD Pro. From a computer generated rendering of the bike, we then have you  return to the shop (if you are in-state) and we test the design for comfort and fit on our Calfee Sizer Bike which gives us real time feedback on the fit. If there are any adjustments to be made to the design, we go back and make the changes in Bike CAD before we start construction. Next we begin the actual construction of the frame, mitering tubes, tacking the frame in our Sputnik Frame Jig. We check the alignment during several steps along the way as we braze the frame in its final configuration. Then we clean-up the fillets and prepare the frame for paint with a light blast in our media blast cabinet. We currently are powder coating and ceramic coating all our own frames in house to ensure a top quality finish. Finally we assemble the new bicycle for pick up at the shop or shipping to your home.