Video: The making of a Condor Leggero carbon frame

Behind-the-scenes video at the Italian factory used by Condor for the making of their top-end race frame

by David Arthur   October 16, 2013  

Here’s a nice video showing the manufacturing of Condor’s Leggero carbon frame in Veneto, Italy. This is the top-end race frame from the London bike shop, as used by the Rapha-Condor-JLT professional team.

All carbon frames are made by hand, even those from the big manufacturers, but some are a bit more involved than others. The Leggero uses the tube-to-tube method, with precisely mitred tubes bonded together. Strips of carbon are strategically wrapped around the tube junctions.  A special jig is used to assemble the various tubes into the desired geometry, before it’s all put in an oven and cured for a specific time and temperature.

The video claims each Leggero and Barachi take a day to build. Condor say the frame is made from a combination of uni-directional and directional high modulus carbon, to achieve the desired level of stiffness. All cables are naturally routed internally, it’s Di2 and EPS compatible and comes with a Deda Nero Supermacy full carbon monocoque fork

The Leggero, while it has been around for a few years, has been constantly updated in that time. They get a lot of feedback from the race time and that has helped evolve the design. As you’d expect for a race frame, there are plenty of key details to boost stiffness. A tapered head tube with 1-1/8” at the top to 1-½” at the bottom bearings up front, a BB30 bottom bracket down below and oversized tubes feature throughout.

8 user comments

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Nice to see small scale manufacture of bike frames! I hope it works out for them.

Did Condor also say where they get the tubes from? Also this does not make much sense "The frame is made with four layers of uni-directional carbon and two layers of directional high modulus carbon" - what did they mean to say?

posted by mythbuster [31 posts]
16th October 2013 - 10:38

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Dedacciai... Recognise the style anywhere

posted by ratattat [18 posts]
16th October 2013 - 13:51

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The carbon fibre itself is manufactured in Japan, and the tubes are manufactured in house, in Italy. We also use some prefabricated tubes from Dedacciai, in the same way that we do with some of steel framesets.

When the tubes are individually manufactured, layers of carbon fibre are built up within a mould -in the same way that a monocoque frame is constructed. During this part of the process, both the alignment and type (uni or multi-directional) of fibres are strategically applied in order to dictate and influence the properties of the structure; obviously some areas need to be stiffer, some more compliant and some require increased levels of impact resistance. We also employ nano technology, whereby the epoxy used to bond the material together contains carbon nanotubes, making it much stronger.

We wanted to highlight that this process is not the same as off the shelf monocoque frames. It is much more costly and labour-intensive, but it allows us to be more flexible, i.e. custom etc...and it also ultimately leads to a higher quality product.

Hope this is helpful.

posted by Condorcycles [1 posts]
16th October 2013 - 14:41

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More crazy moon language! Were Condor and Rapha recently named as joint winners of the Nobel Prize for Bollockology?

posted by robert_obrien [116 posts]
16th October 2013 - 15:50

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robert_obrien wrote:
More crazy moon language! Were Condor and Rapha recently named as joint winners of the Nobel Prize for Bollockology?

Wow- are you a simpleton. Every single world they have used exists in the dictionary.

Fair play for them going on here to answer the questions.

If you want nonsense (made up words) looks at brands like Pinerello and Castelli.

George Alagiah is your father

posted by Casbon86 [5 posts]
16th October 2013 - 16:19

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Casbon86 wrote:
robert_obrien wrote:
More crazy moon language! Were Condor and Rapha recently named as joint winners of the Nobel Prize for Bollockology?

Wow- are you a simpleton. Every single world they have used exists in the dictionary.

Fair play for them going on here to answer the questions.

If you want nonsense (made up words) looks at brands like Pinerello and Castelli.

+1
Having worked with CFRP, I could quite legitimately state that it looks like they are using pre-preg for the wrap of the tube junctions. If you don't understand the terms, robert_obrien, it doesn't mean it's bollocks!!
Even if you don't have any engineering experience, I'm pretty sure that if you thought about it, you could figure terms like uni (one?) and multi (many?) directional out... hopefully Thinking

posted by pwake [242 posts]
16th October 2013 - 17:06

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Oops. That comment went in the wrong place. It was actually referring to the 'italian prayers' commentary in the video. Which chimes with the tone of the Rapha Continental videos. Do your bike rides feel like prayers and cycling through beautiful scenery in the mist? Mine feel like Grand Theft Auto commentated by Roy 'Chubby' Brown.

posted by robert_obrien [116 posts]
17th October 2013 - 14:20

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Yeah sure.....

posted by J90 [29 posts]
19th October 2013 - 0:19

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