fustle bikes donard causeway steel collaboration gravel bike northern ireland

FUSTLE X DONARD

CAUSEWAY COLLABORATION

IT ALL STARTED WITH AN IDEA

THE FUSTLE X DONARD CAUSEWAY COLLABORATION

If you have made it this far, then you probably share our love of all things bicycles, especially the dark art of hand crafting a new frame out of its raw ingredients.

This project started out as a discussion between Owen from Donard.cc and our director Alastair, and quickly started to grow some legs when we got excited about producing a hand made version of our successful Causeway frame, which was designed and tested right here on the shores of Northern Ireland.

Jump forward a few months and we have just finished our first hand made Donard Causeway Collab frame, and the plan now is to add this model into our product range for those discerning gravel enthusiasts looking for a top quality steel (Reynolds and Columbus) gravel bike with attitude.

You can see our first episode of the process over on our youtube channel, or via following the video link below.
If you are interested to find out more or want to have your name added to the waiting list (these frames are made induvidually and will require a deposit to be placed in order to secure your new bike) please get in touch via the contact form below, or via email to hello@ridefustle.com

NO MORE CAD DESIGN

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.

MEASURE TWICE, CUT ONCE...

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.

SWEAT THE SMALL STUFF

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.

#steelisreal