By hook or by crookA visit to Dirk Zedler

Henri Lesewitz

 · 28.03.2019

By hook or by crook: A visit to Dirk ZedlerPhoto: Henri Lesewitz
By hook or by crook: A visit to Dirk Zedler
Dirk Zedler has been fighting against mishaps for over 25 years. We visited the Zedler Institute for Bicycle Technology and Safety in Ludwigsburg, where photography is normally strictly forbidden.

25 years of battling bunk - Dirk Zedler relentlessly uncovers defective products in the bicycle industry with expert reports and extensive laboratory tests. We were also allowed to discover the most secret corners of the Zedler Institute for Bicycle Technology and Safety in Ludwigsburg, where photography is normally strictly forbidden.

On 1 April 1993, graduate engineer Dirk Zedler sat down at a desk in a converted children's room and decided to become a bicycle expert with immediate effect. It was the time when the lightweight construction craze in the mountain bike scene was blossoming horribly. Cranks and stems were milled to the limit, handlebars and frames were laminated "on the off-chance". The stuff broke by the dozen.

Nevertheless, the first few years were tough for Zedler. He toyed with the idea of quitting. The issue of safety did not play a major role for the companies at the time. The engineers were more concerned with fine-tuning the technical refinements. Disc brakes, suspension, gears - there really was a lot to do.

With the triumph of carbon, laboratory tests became increasingly important from the mid-noughties. Zedler, who in the meantime had made a name for himself with test stands for the racing bike magazine TOUR, gradually expanded his company into a test laboratory. At the same time, he also developed the laboratory test together with the associated testing machines for Delius Klasing Verlag, which also owns BIKE and FREERIDE.

Since the Zedler test laboratory was restructured as an institute in 2010 - which required proof of scientific work - companies from Asia, Europe and the USA have been sending frames and parts to have their durability tested almost on a daily basis. The industry had discovered the topic of safety for itself. And Dirk Zedler undoubtedly played a large part in this. In BIKE 4/2019 we have dedicated a detailed portrait story to the tireless campaigner for product safety. A photo gallery is available here.

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   BIKE 4/2019 is available at newsagents until 1 April and beyond in our <a href="https://www.delius-klasing.de/zeitschriften" target="_blank" rel="noopener noreferrer">online shop</a> and as a digital edition for all devices - while stocks last.Photo: Delius Klasing Verlag BIKE 4/2019 is available at newsagents until 1 April and beyond in our online shop and as a digital edition for all devices - while stocks last.  When the sun begins its day's work, Dirk Zedler is usually already at the institute. His shift often starts as early as 5.30 am. It's not just the window fronts of the head office that exude the flair of exhibition showcases. Every window of the new, ultra-modern institute building is decorated with a bicycle.Photo: Henri Lesewitz When the sun begins its day's work, Dirk Zedler is usually already at the institute. His shift often starts as early as 5.30 am. It's not just the window fronts of the head office that exude the flair of exhibition showcases. Every window of the new, ultra-modern institute building is decorated with a bicycle.  The central office floor is a tribute to the history of bicycles. Although many of the rarities are on loan, it is immediately clear how passionate Dirk Zedler (photo) is about bicycles.Photo: Henri Lesewitz The central office floor is a tribute to the history of bicycles. Although many of the rarities are on loan, it is immediately clear how passionate Dirk Zedler (photo) is about bicycles.  The laboratory area is strictly shielded. There are no windows. Visitors must hand in their mobile phones before entering. Testing expertise is the institute's greatest asset. Zedler fears nothing more than intellectual theft. Here, a Syncros handlebar is undergoing the simulation of a tough off-road ride. Pedalling uphill, downhill and an overload every 4000 load changes, which corresponds to a fall or an unsuccessful riding manoeuvre. Incidentally, the waste heat from the pneumatics is used to heat the building.Photo: Henri Lesewitz The laboratory area is strictly shielded. There are no windows. Visitors must hand in their mobile phones before entering. Testing expertise is the institute's greatest asset. Zedler fears nothing more than intellectual theft. Here, a Syncros handlebar is undergoing the simulation of a tough off-road ride. Pedalling uphill, downhill and an overload every 4000 load changes, which corresponds to a fall or an unsuccessful riding manoeuvre. Incidentally, the waste heat from the pneumatics is used to heat the building.  The test stand's sensor system registers every deviation. As soon as damage occurs, it switches off. An engineer then checks whether the component is damaged or whether just a screw has loosened.Photo: Henri Lesewitz The test stand's sensor system registers every deviation. As soon as damage occurs, it switches off. An engineer then checks whether the component is damaged or whether just a screw has loosened.  The sticker warns against further use: much of what was on the test machines is scrap afterwards. Especially after the so-called impact tests, in which the load limit is tested.Photo: Henri Lesewitz The sticker warns against further use: much of what was on the test machines is scrap afterwards. Especially after the so-called impact tests, in which the load limit is tested.
  "Gallery of failure" is what Zedler calls the showcase trellis in the basement of the company. A cabinet of horrors, because the parts on display are evidence of real accidents.Photo: Henri Lesewitz "Gallery of failure" is what Zedler calls the showcase trellis in the basement of the company. A cabinet of horrors, because the parts on display are evidence of real accidents.  In his 25-year career as an expert valuer, Dirk Zedler has seen everything, from technical botches to material collapse due to faulty assembly. There is no such thing as absolute safety, he says. Anything can break. It is important to fit parts correctly and in accordance with the manufacturer's instructions - ideally always using a torque spanner.Photo: Henri Lesewitz In his 25-year career as an expert valuer, Dirk Zedler has seen everything, from technical botches to material collapse due to faulty assembly. There is no such thing as absolute safety, he says. Anything can break. It is important to fit parts correctly and in accordance with the manufacturer's instructions - ideally always using a torque spanner.  If a part fails, the damage is immediately and meticulously documented, for which the Zedler-Institut even has its own photo studio. The frame and parts are then sent back to the manufacturer. What can remain in the institute is reworked into decoration. These former frames here will serve as pen holders in future.Photo: Henri Lesewitz If a part fails, the damage is immediately and meticulously documented, for which the Zedler-Institut even has its own photo studio. The frame and parts are then sent back to the manufacturer. What can remain in the institute is reworked into decoration. These former frames here will serve as pen holders in future.  Rims in a former life - reborn as coat hooks after "death" on the testing machine.Photo: Henri Lesewitz Rims in a former life - reborn as coat hooks after "death" on the testing machine.  Also pretty: a wall clock made from an aero rim and brake disc.Photo: Henri Lesewitz Also pretty: a wall clock made from an aero rim and brake disc.  The "Walk of Fame" leaves no room for doubt: The company is one of the most renowned testing institutes for bicycle technology and safety in the world.Photo: Henri Lesewitz The "Walk of Fame" leaves no room for doubt: The company is one of the most renowned testing institutes for bicycle technology and safety in the world.
  All test benches are built at the institute. Adapters and small parts are manufactured in Jürgen Haag's workshop if required.Photo: Henri Lesewitz All test benches are built at the institute. Adapters and small parts are manufactured in Jürgen Haag's workshop if required.  The upper floor is called the "museum". The seminar room with countless historical bicycle exhibits is rented out for training courses or conferences.Photo: Henri Lesewitz The upper floor is called the "museum". The seminar room with countless historical bicycle exhibits is rented out for training courses or conferences.  The walls are decorated with bicycles, the showcases full of parts and everything that has to do with cycling. This Playmobil still life is one of them.Photo: Henri Lesewitz The walls are decorated with bicycles, the showcases full of parts and everything that has to do with cycling. This Playmobil still life is one of them.  The bikes on display are organised by theme. In the MTB corner, you will find early fullys as well as rarities such as this legendary Slingshot, in which a steel cable replaces the down tube - which should provide extra comfort.Photo: Henri Lesewitz The bikes on display are organised by theme. In the MTB corner, you will find early fullys as well as rarities such as this legendary Slingshot, in which a steel cable replaces the down tube - which should provide extra comfort.  The top tube of the Slingshot is connected to the seat tube via a leaf spring, while a spring at the bottom of the bottom bracket keeps the steel cable under tension. This allows the frame to absorb road shocks. At least a tiny bit.Photo: Henri Lesewitz The top tube of the Slingshot is connected to the seat tube via a leaf spring, while a spring at the bottom of the bottom bracket keeps the steel cable under tension. This allows the frame to absorb road shocks. At least a tiny bit.  When Dirk Zedler gives a tour of the museum, he is in his element. He has a story to tell about every bike and every part.Photo: Henri Lesewitz When Dirk Zedler gives a tour of the museum, he is in his element. He has a story to tell about every bike and every part.
  The first years as a bicycle expert were so tough that Dirk Zedler had to be financially supported by his parents. Today, Zedler's institute has 23 employees and inspects around 500 frames and 1,200 accessories per year - from carbon fibre bikes to bicycle bells.Photo: Henri Lesewitz The first years as a bicycle expert were so tough that Dirk Zedler had to be financially supported by his parents. Today, Zedler's institute has 23 employees and inspects around 500 frames and 1,200 accessories per year - from carbon fibre bikes to bicycle bells.



You can find the portrait story about Dirk Zedler in BIKE 4/2019. You can read the issue in the BIKE app (iTunes and Google Play) or in our online shop order - while stocks last:

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