Singletrack

Our final stop was to see the sample frames being masked
off for the two-tone paint. I was astounded to see three of
Willing’s workers precisely taping off areas for the two-tone
paint job with craft knives and tweezers to put the masking
film exactly where it was needed. All by eye, referring to a
colour printout of the frame. And this wasn’t the prototype
production line. This was every single painted frame. Such
hands-on work was surprising. Even after the frames came
back from painting, the decals – stacked ready for each frame
and colour – were applied by hand, by eye, with stickered
stripes perfectly matching painted accents, indistinguishable
from each other. A final ‘Saracen’ logo, again by eye, and the
frame was ready for final clear coat and inspection.
What now?
That was the first sample run of a model-year process that
takes around 18 months in total, from initial design to shop
floor. Assuming that models from that sample run pass safety
testing and Saracen’s approval, they will be air-shipped to the
UK for final approval, test riding and both studio and trail
photography for the 2018 brochure. They’ll then need to be
presented to the dealers and press, ready for orders to be taken
and reviews written. Meanwhile, there are the 2019 models
waiting in the wings with their own set of challenges and
component specs for products that haven’t been invented yet.
Hand-laid decals go onto the painted frames.
The final stage of the process.
Shooting for the glossy catalogue.
Photo: Saracen Bikes
22
Thanks to Saracen Bikes, who paid for the
transport and accommodation on this trip.