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Through the keyhole with Trek’s carbon fibre manufacturing and custom painting processes

This video takes you on a tour of Trek’s Waterloo, Wisconsin factory, where they still make many of their top-end bikes like the Madone 6 and 7, and includes their custom paint and bike builder facility Project One.

Trek Bicycles, founded in 1976, actually started making their first carbon fibre bicycles frames with the introduction of the 5500 and 5200 road bikes in 1992. They used Trek’s proprietary OCLV (Optimum Compaction, Low Void) manufacturing process, which they still use to this day.  While many of the cheaper carbon bikes are now made in Taiwan, they still make their top of the range models in the US.

And if you order a bike through Trek's Project One website, this is where they are assembled. The custom bike builder lets you choose from a raft of paint options as well as specifying the wheels, groupset and components.

David has worked on the road.cc tech team since July 2012. Previously he was editor of Bikemagic.com and before that staff writer at RCUK. He's a seasoned cyclist of all disciplines, from road to mountain biking, touring to cyclo-cross, he only wishes he had time to ride them all. He's mildly competitive, though he'll never admit it, and is a frequent road racer but is too lazy to do really well. He currently resides in the Cotswolds.

4 comments

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Punkass [13 posts] 2 years ago
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Ahem...1976.  3

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titusrider [25 posts] 2 years ago
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I do quite fancy one of these, a madone in either Jens or Spartacus colours ideally, however I cant get over the fact that when im spending that much money I would want different finishing kit and probably custom geometry.

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barkingfishes [26 posts] 2 years ago
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Geez a job ...

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Al__S [960 posts] 2 years ago
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Did wonder how much detail they'd go into on the moulding and curing process. not too surprised to see that it was "almost no detail at all".