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...."We gotta make those bikes one at a time":
If this could be achieved, then the chance of specifications, braze-ons, or bike tubing getting confused would be eliminated.

The Problem:
If we made bikes one at a time, our setup times would be astronomical. For instance, we used one machine (Pa Pa Bear) for several processes in making a bike. Each process setup time could be as long as 15 minutes. Not only that, but if Dennis was using Pa Pa Bear for one process, Todd would have to wait until the machine was not in use. This would add even more time.

The solution:
Eliminate setup times all together: To eliminate setup times we needed lots of machines that were permanently set up for each specific process.

Another problem:
Our frame shop is small: There would have to be a lot of machines, and they would have to be small enough to fit into our small frame shop. After searching for quite a while, we discovered that no manufacturer made small machines that were good enough to do the job.

The solution:
Call in a Rare Bird: We're lucky enough to have some rare birds of our own here at R+E Cycles. Dennis Bushnell, our head frame builder, is not only a frame builder but a very creative and talented machinist. He rose to the challenge that I gave him. He set to work designing and building small machines using scrap metal and parts from old machines we had laying around the shop that we weren't using. Some of the machines he created are truly amazing.

Here are some photos of just some of the improvements we made this winter.

As I said, these are just a small sampling of the improvements we were able to accomplish this winter in the frame shop. Our frame building method will be more efficient, but more importantly, we'll be able to build an even better quality bike than before. We want to invite you in to tour our new digs. Feel free to come in anytime during the week and we'll give you a free tour!

I can't wait for this season to start....oh wait a minute...it never ended...what year is this anyway?

February, 2006 - Dan

The affordable Rodriguez production and custom bikes are carefully handbuilt, one at a time, every step done by hand, by humans, here at R+E CYCLES. We carefully design the angles and lengths for each size of bike. One at a time, the tubes are cut with precision care. Each weld is hand done by a skilled welder. The bicycle is assembled by a professional mechanic - even the wheels are handbuilt! Every process is done by a human. Not one of the steps is done by an automated machine. And when you purchase from us, we make sure your new bike fits you perfect! Afterall, a good fit is the key to enjoying your new bicycle.