Merlin Factory Tour ~

What does it take to make the finest titanium bikes in the world? Our tour of the Merlin Metalworks factory in August 2003 answered that question for us. The following pictures will probably make it easier for you to see the dedication to impeccable quality that makes Merlin the very best.

Double click pictures for enlarged view.

How it all begins ~

30 foot tubes of genuine Haynes seamless aircraft certified titanium tubing, the finest there is.

Swag machine to reshape tubing ~

Additional shaping machinery ~

Custom shaped tubings ~

All done in-house, all seamless!

Precision machine mitering ~

Merlin has the closest tolerances of any frame in the world today. The fact is Merlin set the standards that all other serious builders now strive to match.

Completed precision miters ~

Solid titanium bottom bracket stock ~

Only Merlin takes the time to do this kind machining! The precision of the bottom bracket cut determines the precision that the rest of the frame can be held to. Skimp here, as every other builder does, and the most you can hope for is second best!

Finishing tools for bottom bracket ~

This is one amazing machine! To the right, under a constant fluid batch, all the various steps of machining are actually done. What you are seeing is the assortment of cutters and bits that the hydraulic arm will reach up and grab between each step of the machining process.

Cutting the solid core bottom bracket ~

Here is the cutter going to work. Note the constant fluid bath. The bath lubricates, controls heat, and clears away the cutting residue.

Half finished bottom bracket weld ~

The smallest welding bead is required because the miters and alignments are so precise.

Completed bottom bracket welds ~

How is that for precision! No grinding and hiding needed here.

Frame specific seamless Haynes tubing ~

Each tube on every size of each model is arefully shaped, inside and out, to guarantee the world's finest Ti ride. No other builder approaches this kind of precision or attention to detail. Size specific tubing is one of the prime reasons that no other builder approaches the Merlin ride.

Perfectly mitered head tube joints ~

This picture is from a random frame in production. Each and every Merlin meets this same standard of excellence.

Completed head tube welds ~

Once again, a random frame in production. Every frame receives this same state-of-the-art weld quality that has made Merlin a legend around the world.