XXVI.SEVEN / AEIGHT RACER BLOG / STEEL MARCH
IT STARTS WITH A BOX OF TUBES - IN SUSSEX STEEL WE TRUST...
In actual fact, it starts with an idea, a chat, or a phone call, and then a bike-fit! People who are interested in a bespoke frame usually have a fairly good idea about what they want, or at least what they want it to do. In this case the customer already has plenty of options so we could afford to be quite specific when building his frame. Our XCO race focused hardtail mountain bike frame, called the ÄXE, fitted the bill perfectly.
Once we’ve had a proper chat (over a cup of tea) about what it is that you/we want to achieve, the next step is a bike-fit to nail down the measurements which we’ll use to design your frame and bike. This can be done on a bike that you’re already comfortable on, or completely from scratch. Like most bike-fits we start with some flexibility and injury assessments, before looking at your feet and cleats. We then focus on the saddle position, before finally addressing the bar/lever/control position. This gives us two ideal points in space in relation to the BB and that’s where the design starts!
Next, we take a blank sheet of paper and draw the BB, saddle and bar position on it. We work backwards from the bar position with specific stem, spacer, and fork measurements, along with our intended head angle, to determine a stack and reach for the frames headtube as well as the length for that tube. The BB and saddle position dictates the seat angle to a certain extent, and we also apply what we know to shuffle everything into position which will fit the rider perfectly, whilst creating something which will transform the trail into a ribbon of silk! Then we join up the dots and calculate the tube lengths needed.
On our second consultation we discuss the final build, sign off the frame and order everything we need to get started! We sometimes do this over the phone, but it’s better in person.
Once the frame materials arrive, we set up the jig to replicate our design. Every frame is a one-off, so the jig is set up from scratch every time. We put the BB shell through several processes to modify it to take di2 wires and/or a dropper routing and then mitre the seattube to fit it perfectly. The headtube is cut to size and fixed into the jig, and the downtube is mitred to fit the headtube and the BB shell. The front triangle is completed by mitreing the toptube and then I drill the cage bosses, a couple of breather holes, and then we tack and braze the seattube to the BB.
The BB and seattube get tracked for alignment, the downtube mitre gets a tweak and is then tacked in place along with the toptube, and the final alignment of everything is re-checked. I like to get all four brazes done in one go – once the brass is flowing and everything is hot I find it easier to work with, so I aim to get a first and second pass of braze on all four joints, all in one go, rather than reheating the joints several times. There’s a lot going on in a short space of time and you’re constantly considering several different things at once – after this, it’s definitely time for a much-needed cup of tea whilst the frame cools down!
The rear dropouts are bolted into the jig and the stays are cut and mitred – the seatstays are fairly easy, but my “Valknut” rear end means that the Hellenic seatstays are hard work to get perfectly mitred. The addition of the Full-Mount/UDH rear end has added some additional complexity, but it’s worth it to be able to use the new rear mechs. Chainstays get tacked, aligned, and brazed first, then one side of the seatstays, and then the final seatstay. This process takes ages because you need to be very careful about checking the alignment of so many different pieces and factors! Another cup of tea and you’re ready to start the clean-up!
Usually, I file the front of the frame before starting to braze the rear – this makes sure that everything is as it should be and gives you a chance to get one step ahead. Then the rear end gets filed as you go. By the time you’re finished brazing there should hopefully be minimal sanding, cleaning, and tweaking needed to get a nice finish. I check the alignment one final time, reem and face the headtube, reem the seatube, face and chase the threads in the BB, and then it’s time for my favourite job - fittings…
Fitting the cage bosses and hose guides with silver solder is a lovely way to finish – it’s a much more delicate balance of heat than with brass, and the silver flows really fast. You need just the right amount of silver and perfect timing with the torch. Hard to perfect, but rewarding when it’s done! A quick final clean up and the frame is ready for a splash of colour…
Photos by Glen Whittington
2026.RIDERS - GLENWHITTINGTON
#aeightracer – Bike Rider / Framebuilder / Mechanic - Glen started racing in 1998, initially specialising in XCO, XCM, and Solo 24-Hour Mountain Bike. He became a mechanic in 2002, working in shops and also for professional race teams. During this time he spent more time racing ‘Cross and Road, and then also TT. In 2013 he built his first bespoke frame and then spent several years at Roberts learning the art. Since then he’s designed, tested and now sells his own frames/bikes to the public as part of his ÆIGHT brand - you can find his business Instagram account here.
GOT WHAT IT TAKES TO RACE WITH US?
We’re always looking for riders to be part of our ÆIGHT CØLLECTIVE. The #aeightbikeco is about doing things a little differently - Rather than a jersey being the common theme, we kit our riders out with bespoke steel bikes and handbuilt wheels made in our Sussex workshops, the ÆIGHT WHEELWØRKS and the ÆIGHT MANUFACTØRY. We then support each other at events and races regionally, nationally and internationally - whether that’s for mountain bike, ‘cross, gravel, crit, road or TT - it’s what we call, the #aeightbikeco
The best part is that we’re not asking you to leave your team or club - that includes racing in your club/team kit. We’ve got certain brands that we work with, mostly so we can standardise shared equipment, but your own sponsors and clubs are almost always welcome. We have some strict qualifying criteria but don’t be put off by this – if you’re interested in being part of the #aeightbikeco then please get in touch by emailing your racing CV to eightbikeco@gmail.com
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