Crafting Perfection: Behind No.22’s Manufacturing Magic
Every now and then, I get the opportunity to visit exceptional places. This time, the folks at No.22 invited me to see what they do best: creating bespoke pieces where every detail counts.
Located in Johnstown, upstate New York, I was fortunate enough to spend several days collaborating with the team and photograph their process. And let me tell you: every step is a visual treat if you enjoy peeking behind the scenes and gaining an insight into what goes on to create some of the best titanium bikes on Earth.
Let's begin, shall we? Each frame starts with a bundle of tubes that need cutting, milling, and butting. Although the process is quite streamlined, selecting the right tubes for each frame is crucial. Almost every tube is mechanically adjusted for variable wall thickness based on its intended use – gravel, road, MTB, or track, and of course, the rider's size and weight, also play a significant role in this process.
After that comes the lengthy process of sanding and preparing the tubes for welding. Each tube is sanded to give them an initial polish and to ensure they are free of any impurities that could affect welding. Each tube undergoes at least four or six different grits on the belt sander, which is a considerable task that may not be necessary but, with the quality standards in place here, it's essential. For the carbon bonding process involved in ISP carbon variants such as Aurora and The Reactor is a thing of beauty when you comprehend the extent of preparation, timing, and skills required to make it happen flawlessly.
But here is my opinion on the secret sauce of No.22’s next-level frame building: Frank and Sam, the welders, are both exceptionally skilled at their craft. This may sound obvious, but I'd like to elaborate. Frank has been welding bikes since high school, meaning he's been constructing frames longer than I have existed! His extensive experience sets him apart from anything I've encountered before. We all know that when metal tubing is heated and welded; it can warp, shrink, and deform. Consequently, bike frames typically require adjustments post-welding to ensure perfect alignment. However, during my brief time with Frank, I observed him frequently moving back and forth between his welding jig and the alignment table. And that isn’t due to uncertainty or anything like that, but rather to fine-tune his work. Frank's unique approach to working with titanium results in frames that require minimal to no adjustment when removed from the jig. This level of craftsmanship may seem like a minor detail, but trust me, it holds immense value.
I'm going to go off on a tangent here, but I need most of you, the readers, to understand how crucial Frank’s technique is. If you’ve ever seen a frame break at the weld, you’ve probably noticed how the tubes spring back and usually misalign. This is because, most of the time, welding forces tubes into place, and locks them together. This results in a constant tension applied within your frame, whether or not you’re riding it.
Now, these tubes exerting constant forces are like sailing on an ocean with unpredictable waves that you have no control over. In contrast, a perfectly aligned frame creates a smooth lake, enabling you to deploy the full potential of your ship. Giving you extra control, making your ride smoother and more efficient.
In other words, making you faster.
So that's for the frame building aspects, but one thing that made No.22 famous is their anodizing and general finishing process. Yes, you could get a raw titanium frame, but you'd miss out on all the crazy things you can do with Titanium anodizing. And the work to make it happen is on par with the rest of their workflow. Each frame will be polished and masked at least three times between all the finishes, creating this contrast between the slick and vibrant anodized parts and the matte texture from the Cerakote. Three perfect maskings are required to avoid any unintended double lining, and Daryn who’s in charge, clearly has an eye for details.
The final phase is, of course, the Cerakote (or wet paint) that is sprayed onto the frame. My personal experience with Cerakote is still quite limited, but here's what I know. Cerakote isn’t paint, nor is it powder coating. It’s a high-performance ceramic-based finish used in various industries for its durability. Regarding durability, you’ll often find Cerakote on guns or refinished cameras - items that typically endure heavy use. When Daryn, who handles all the spraying, explained how it works, it made perfect sense to slate a frame in Cerakote instead of painting it with regular wet paint. It's lighter, more resistant to scratches, and because it can be sprayed thinly, you don’t have that distinct demarcation between painted parts of your frame and raw titanium that some other builders may have.
Part of the frame building process, but distinctly in a category of its own, is all the additional Titanium 3D printing that occurs for No.22’s fully integrated stem, their seatmast, computer mount, and a few other components. I will dive deeper into my experience with the 3D printed stem during my review of the Little Wing I'm currently testing. However, Santiago, who oversees the design and engineering of these parts, has accomplished an impressive feat in creating unique pieces that make your build even more distinctive and cohesive. It is also worth mentioning that Titanium 3D printing is just a mind-boggling process in itself, and having NASA-grade components on your bike makes you feel on another level.
So what's my take on No.22? After spending a few days with the team, I can safely say that the bikes they make are part of why I'm falling in love with the brand. No.22 is indeed a very high-standard company, constantly striving to be at the forefront of titanium fabrication and finishing. However, it's first and foremost a tight group of incredibly skilled individuals, pouring every drop of effort into their creations. There's truly something infused in each frame they produce, something you usually only find with an independent frame builder but very rarely in a team.
You're not really buying a bike at No22; instead, you're paying for over a century of combined experience, distilled into a few kilos of Titanium.
Just before finishing this article, I want to thank the entire team: Michala, Scott, Bryar, Frank, Sam, Santiago, Brad, and Daryn for making my stay such an incredible experience. And of course Bryce and Mike for giving me this amazing opportunity.
For all my readers, stay strapped, there is more No.22 content coming soon, with some I’m especially proud of.
So… You want to know how it rides?
🎞: kodak ColorPlus 200
📷: Leica M6 / M4
📍: Johnstown NY
