How We Do What We Do
The Ruckus carbon fiber repair process is developed off the latest in aerospace carbon fiber repair technology. We couple this with our intimate knowledge of bicycle design and the latest in advanced material science.
Step 1: Damage Assessment
We assess bike frames using the latest in non-destructive technology, including infrared, ultrasound scanning, acoustic feedback and fluorescent penetrant dyes in order to form an entire perspective of the damaged area. We pair this investigation with our knowledge of carbon fiber construction techniques, long-working bicycle design and engineering expertise to craft the perfect repair, individually tailored to each bike frame’s make and model.
Step 2: Damage Removal
Safe repair starts with accurate and complete removal of all damaged material. Once damage removal is complete we design a taper to conform to the latest aerospace repair standards. In this process, we note any material findings and orientations. Coupling the tapered design with this material information yields a repair that matches the original design intent.
Step 3: Material Choice and Lay-Up Design
We then design a custom lay-up repair schedule (the sequenced layering of pre-impregnated carbon fiber sheets) based on information gathered in the assessment and removal steps. Each repair is unique in its entirety, so we make certain to fully match the original intended design of the frame. We source our raw carbon fiber from the same high-performance companies used by the aerospace industry and other leading bike manufacturers.
Step 4: Casting and Compression
Next, we then apply the custom cut “prepreg” carbon fiber sheets in accordance with our lay-up schedule. We then process the casted frame with the correct amount of heat and pressure in order to ensure the highest quality repair. Different repairs require different compression techniques to ensure an optimal fiber to resin ratio and this process ensures uniformity.
Step 5: Graphic Restoration
Step 6: Ride and Enjoy
All repairs go through an extensive QC process and receive expert detailing before we carefully pack them up and send them off to your door/local bike shop for rebuild. Enjoy your ride!
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