BIKE Project Europe: Real manual labour at frame welder Alutech

Marc Strucken

, Henri Lesewitz

· 11.07.2022

BIKE Project Europe: Real manual labour at frame welder Alutech

Photo: Henri Lesewitz

Genuine manual labour at the frame welder Alutech | ch

If a German bike manufacturer is welding its own frames again for economic reasons, then it is the perfect candidate for our BIKE Project: Europe. We watched Jürgen Schlender from Alutech at work on our "made in Europe" bike.

The BIKE PROJECT: EUROPE is literally taking shape. What we set up as a large field test, a kind of feasibility study at our editorial desks, is now becoming reality in a first step with the frame for our mountain bike project. BIKE editor-in-chief Herni Lesewitz visited the birthplace of our "made in Europe" bike: the cult frame manufacturer Alutech in Schleswig-Holstein.

The reason why Alutech produces our frame lies in the history of this company based in Aschaffel near the Baltic Sea coast. After MTB enthusiast Jürgen took over the shop for sale in 2001, he gradually built up the Alutech brand into a cult forge. As is customary in the industry, production was outsourced to Taiwan after a few years. Due to considerable supply difficulties, Schlender pulled the ripcord in 2021: since then, the boss has been welding all frames himself again. His model range extends from gravel to downhill. The most successful model is the Enduro-Fully Faneswhich also forms the basis for our European bike. And so it has been created over the last few months as part of the BIKE Project: Europe.

Our Europa mountain bike consists of 23 tubes and 55 milled parts. Before the pandemic and its delivery problems, Jürgen Schlender used to get finished frames delivered from Taiwan after 60 days. When he was told that the waiting times were 1.5 years (!) for the raw material alone and another year until they were welded, Schlender picked up the electrode again and welded them himself. | t.

Photo: Henri LesewitzOur Europa mountain bike consists of 23 tubes and 55 milled parts. Before the pandemic and its delivery problems, Jürgen Schlender used to get finished frames delivered from Taiwan after 60 days. When he was told that the waiting times were 1.5 years (!) for the raw material alone and another year until they were welded, Schlender picked up the electrode again and welded them himself. | t.

The CNC milled parts still come from Taiwan, but Alutech is already looking for European alternatives. In any case, 100 per cent European production is not possible for the frame. The bearings for the BIKE PROJECT: Europe, which Alutech uses, also come from Enduro Bearings in the USA. However, European bearings, such as those from SKF, are also available on the market in the high-end segment. | F.

Photo: Henri LesewitzThe CNC milled parts still come from Taiwan, but Alutech is already looking for European alternatives. In any case, 100 per cent European production is not possible for the frame. The bearings for the BIKE PROJECT: Europe, which Alutech uses, also come from Enduro Bearings in the USA. However, European bearings, such as those from SKF, are also available on the market in the high-end segment. | F.

Jürgen Schlender is a craftsman in the very best sense of the word. The Alutech boss is a trained tailor and has already worked for Joop and Jil Sander. This is why he uses templates to cut the tubes to size - which is rather unusual in frame production. He also does the cutting himself freehand with an electric handsaw. | e.

Photo: Henri LesewitzJürgen Schlender is a craftsman in the very best sense of the word. The Alutech boss is a trained tailor and has already worked for Joop and Jil Sander. This is why he uses templates to cut the tubes to size - which is rather unusual in frame production. He also does the cutting himself freehand with an electric handsaw. | e.

The frame for our BIKE Project Europe rests stapled in the frame jig. Here you can see the bottom bracket, which is prepared for the Pinion drive and therefore looks more massive than normal. One thing is already clear: Pinion comes from Baden-Württemberg and therefore fits in well with our plan for an "all-European" bike. But when it comes to the inner workings of the Pinion gearbox, <a href="https://www.bike-magazin.de/a/4876959" target="_blank" rel="noopener noreferrer nofollow">parts from outside Europe</a> have to be used again. | n.

Photo: Henri LesewitzThe frame for our BIKE Project Europe rests stapled in the frame jig. Here you can see the bottom bracket, which is prepared for the Pinion drive and therefore looks more massive than normal. One thing is already clear: Pinion comes from Baden-Württemberg and therefore fits in well with our plan for an "all-European" bike. But when it comes to the inner workings of the Pinion gearbox, parts from outside Europe have to be used again. | n.

A picture is slowly emerging: a massive headset, massive down tube and a sexy curve in the seat tube. Nothing is fixed yet, the tubes are just being adapted to each other. | t.

Photo: Henri LesewitzA picture is slowly emerging: a massive headset, massive down tube and a sexy curve in the seat tube. Nothing is fixed yet, the tubes are just being adapted to each other. | t.

Jürgen Schlender positions everything on the frame jig. Later, our 29er mountain bike will have 160 millimetres of rear suspension travel. The rear triangle is designed for 27.5 inches (called MX or Mullet) because Alutech can do without carbon struts, which in turn have to be imported from the Far East. The boss personally welds these struts. | h.

Photo: Henri LesewitzJürgen Schlender positions everything on the frame jig. Later, our 29er mountain bike will have 160 millimetres of rear suspension travel. The rear triangle is designed for 27.5 inches (called MX or Mullet) because Alutech can do without carbon struts, which in turn have to be imported from the Far East. The boss personally welds these struts. | h.

And this is a portrait of him: Jürgen Schlender, owner of Alutech and bike enthusiast to the core! In addition to his jobs, he has always been active in bike sports himself. And legend has it that he bought the company Alutech and drew his first bike while still in the car: the Wildsau! | u!

Photo: Henri LesewitzAnd this is a portrait of him: Jürgen Schlender, owner of Alutech and bike enthusiast to the core! In addition to his jobs, he has always been active in bike sports himself. And legend has it that he bought the company Alutech and drew his first bike while still in the car: the Wildsau! | u!

The wild boar is a massive downhiller. It now hangs in his office as a trophy alongside various race numbers and souvenirs. His own competition bike became famous and infamous as "the cow". Jürgen had covered it with cowhide (real?) and rocketed down the slopes on it. | r.

Photo: Henri LesewitzThe wild boar is a massive downhiller. It now hangs in his office as a trophy alongside various race numbers and souvenirs. His own competition bike became famous and infamous as "the cow". Jürgen had covered it with cowhide (real?) and rocketed down the slopes on it. | r.

But it's not just the frame of the Wildsau that adorns the Alutech headquarters. This almost historic milling machine also proudly bears the boar's head. However, the machine is by no means an exhibit in Aschaffel, where the company is based. The milling machine is an active part of the machine park and is involved in the production of the Fanes frame. | t.

Photo: Henri LesewitzBut it's not just the frame of the Wildsau that adorns the Alutech headquarters. This almost historic milling machine also proudly bears the boar's head. However, the machine is by no means an exhibit in Aschaffel, where the company is based. The milling machine is an active part of the machine park and is involved in the production of the Fanes frame. | t.

Photo: Henri LesewitzIn fact, these brake boosters from Alutech can only be admired for historical reasons. Company founder Andreas Zimmermann earned his money with them from 1993 onwards. Until he sold the rights to the Alutech brand to Jürgen Schlender in 2001. | e.

Today, Alutech has ten employees who together build everything that Alutech offers. From the "Cheaptrick" trail hardtail, to the "Sennes" downhill bike and the "Punk" gravel bike, to the "Fanes" enduro bike, which the Schleswig-Holstein-based company also offers as "eFanes" with a Shimano EP8 motor. And plenty of customised builds, as evidenced by <a href="https://alutech-cycles.com/cms/bike-galerie/" target="_blank" rel="noopener noreferrer nofollow">its online gallery</a>. | t.

Photo: Henri LesewitzToday, Alutech has ten employees who together build everything that Alutech offers. From the "Cheaptrick" trail hardtail, to the "Sennes" downhill bike and the "Punk" gravel bike, to the "Fanes" enduro bike, which the Schleswig-Holstein-based company also offers as "eFanes" with a Shimano EP8 motor. And plenty of customised builds, as evidenced by its online gallery. | t.

But we digress! Now it's time for the welding. Jürgen has now prepared our frame and is making the first weld seams for the BIKE Project: Europe. A total of almost 75 parts have to fit together in the process. Bearings and other small parts are not yet included. | t.

Photo: Henri LesewitzBut we digress! Now it's time for the welding. Jürgen has now prepared our frame and is making the first weld seams for the BIKE Project: Europe. A total of almost 75 parts have to fit together in the process. Bearings and other small parts are not yet included. | t.

At the <a href="https://www.bike-magazin.de/mtb_news/events_rennen/willingen-bike-festival-highlights-2022-tag-2" target="_blank" rel="noopener noreferrer nofollow">BIKE Festival Willigen</a> then the big moment! Jürgen Schlender sets the last scales in front of the audience and marries the Pinion gearbox to the Alutech Fanes frame. | n.

Photo: Henri LesewitzAt the BIKE Festival Willigen then the big moment! Jürgen Schlender sets the last scales in front of the audience and marries the Pinion gearbox to the Alutech Fanes frame. | n.

The maker and his work. Schlender presents the already beautiful frame - complete with Pinion gearbox and 160-millimetre steel spring shock from Formula (more on this in the next articles on the BIKE Project: Europe). However, the frame of our BIKE Project Europe bike is not yet finished. | t.

Photo: Henri LesewitzThe maker and his work. Schlender presents the already beautiful frame - complete with Pinion gearbox and 160-millimetre steel spring shock from Formula (more on this in the next articles on the BIKE Project: Europe). However, the frame of our BIKE Project Europe bike is not yet finished. | t.

In the next steps, our frame - like all frames from Alutech production - has to undergo various further procedures. Before the frame is ready for use, it has to be cured. This takes place in a complex process that Alutech has carried out by a partner company in Bulgaria. | t.

Photo: Henri LesewitzIn the next steps, our frame - like all frames from Alutech production - has to undergo various further procedures. Before the frame is ready for use, it has to be cured. This takes place in a complex process that Alutech has carried out by a partner company in Bulgaria. | t.

We don't know whether this is wellness for a mountain bike frame. But after hardening, the frame is cleaned in six different baths. And because we don't just want our Special Fanes version to gleam with bare aluminium, Alutech has also come up with a custom paint finish. | t.

Photo: Henri LesewitzWe don't know whether this is wellness for a mountain bike frame. But after hardening, the frame is cleaned in six different baths. And because we don't just want our Special Fanes version to gleam with bare aluminium, Alutech has also come up with a custom paint finish. | t.

After polishing and painting, the frame for the BIKE Project: Europe now looks like this. Bright green decals and the model name on the down tube - this is the first result and souvenir from our visit to the German bike manufacturer Alutech. | h.

The next step is to visit the Gearbox specialists Pinion in Denkendorf, Baden-Württemberg, where the drive for our "made in Europe" bike was created.

Marc Strucken

Editor

Marc Struken is a passionate bike journalist and editor at Delius Klasing Verlag. After working in radio, radio, TV and online marketing, he has been contributing his experience to digital content for BIKE, EMTB, FREERIDE and MYBIKE since 2022 - whether mountain bike, gravel or road bike.

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BIKE Project Europe: Real manual labour at frame welder Alutech

Marc Strucken

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