Before any colour gets laid down, we apply some masks in the negative shape of what we want to be visible on the frame. In this case, we are applying a Silver Leaf, so the mask will enable the application of a glue, when it is more commonly used for a 2nd colour of paint.

The glue is water based, so is applied via the paint gun over the masked area.

3 Coats are applied with some time in between which allows it to go tacky before any silver foil is introduced.

Once the adhesive is ready, the Silver Leaf is carefully applied. Once the mask is removed, we are left with only the areas that we want, and the excess is carefully brushed away. Once the whole frame is complete, a clear coat is applied in the spray booth to protect the frame, its paint and the silver leaf.

The current causeway frame was designed using Computer Aided Design (CAD) software. When we started to discuss this project with Owen from Donard, it became clear that the process of producing this steel causeway was going to require a much more analogue approach to design.

Once Donard had a drawing with all of the critical dimensions and geometry, we set about preparing the tubing by cutting to length first, then creating the mitre joint that required great accuracy to ensure a solid junction for the weld to penetrate later. This was achieved using Owen mill and various size cutt bits specifically chosen to match the part of the frame that each tube would be welded to.

Before the tubes are welded into a finished frame, there are lots of small details that need to be taken care of before anything is tacked together. Cable routing was planned and holes drilled for this, as well as bottle bosses and brake mounts drilled and braised into place.