Portfolio

Recent Builds

A selection of our custom bicycle frame designs and builds — from geometry specification and engineering through to finished assembly.

The Nomad Trekking

Steel · Rohloff Speedhub 500/14 · Gates Carbon Drive · Shimano Deore XT · Fox Racing Shox

The Nomad Trekking is a robust, low-maintenance expedition machine. The drivetrain pairs a Rohloff Speedhub 500/14 with a Gates Carbon Drive — silent, grease-free, and built for the long haul. Stopping power comes from Shimano Deore XT hydraulic disc brakes. A Fox Racing Shox suspension fork and Canyon S15 VCLS 2.0 27.2mm CF seatpost handle rough terrain, while Schwalbe Marathon Mondial 50-622 — virtually puncture-proof — provide grip across any surface. The cockpit is finished with a Ritchey setup. Luggage is handled by a Tubus rear rack. Power comes from a SON 28 dynamo hub feeding a Forumslader V6 integrated in the frame — converting dynamo output to USB charge at any speed, with cable routing through a Cinq5 Expander keeping things clean. Via Bluetooth, the Forumslader connects to a companion app (iOS/Android) logging speed, distance, altitude, gradient and battery data. A Connect IQ datafield is available for Garmin computers. GPS track recording requires a separate device.

Titanium-Look Expedition

Columbus Zona Steel · Rohloff Speedhub 500/14 · Gates Carbon Drive · SON 28 Dynamo · Shimano Deore XT

The Titanium-Look Expedition is the ultimate low-maintenance travel machine. The frame is a high-grade Columbus Zona steel, bead-blasted and immediately powder-coated with a transparent varnish — giving it the raw industrial look of titanium while retaining steel's superior vibration damping. The drivetrain pairs a Rohloff Speedhub 500/14 with a Gates Carbon Drive belt: a closed, oil-bath gear system with a grease-free belt that stays silent and efficient through dust, mud, and thousands of kilometres. Braking is handled by Shimano Deore XT hydraulic disc brakes. For maximum grip on unpaved terrain, the bike runs wide Maxxis Ikon 29 x 2.35 tyres. Comfort comes from an Ergotec PM-705N parallel-suspension seatpost and a Surly Moloko handlebar offering multiple hand positions. The headset is a Cane Creek 40 EC ensuring precise, play-free steering. The expedition setup is completed by a Tubus Logo rear rack and Surly Nice Rack at the front with three horizontal rails, plus SKS Bluemels fenders for all-weather readiness. Power is provided by a SON 28 dynamo hub, feeding the SON Edelux II headlight and a Forumslader V6 integrated into the headtube — converting dynamo AC power to stable USB charge at any speed, with cable routing through a Cinq5 Expander keeping the cockpit clean. Via Bluetooth, the Forumslader connects to a companion app (iOS/Android) logging speed, distance, altitude, gradient and battery data. A Connect IQ datafield is available for Garmin computers. GPS track recording requires a separate device.

Felix GRX Di2 Gravel — The Precision All-Roader

Steel · Ritchey WCS Carbon Gravel Fork · Shimano GRX Di2 2x11 · PRO Vibe Carbon

The Felix GRX Di2 Gravel is engineered around a custom lightweight steel frame paired with a Ritchey WCS Carbon Gravel fork. The frame utilizes a stress-free endurance geometry, characterized by an increased stack height and a stabilized wheelbase to optimize long-distance ergonomics and reduce skeletal strain. For expanded utility, the frame includes integrated mounting points specifically designed for a Racktime rear rack system. The drivetrain consists of a Shimano GRX Di2 electronic 2x11 groupset, providing programmable, high-torque shifting. Gearing is configured with Shimano GRX 48/31T double chainwheels and an 11-34T cassette, offering a wide-ratio spread suitable for both technical inclines and high-cadence road sections. The cockpit and seating utilize a professional PRO Vibe finishing kit, featuring a PRO Vibe stem and handlebar for maximum front-end stiffness, complemented by a PRO Vibe Carbon seatpost — which functions as the dedicated internal housing for the Di2 battery, ensuring the electronic system remains entirely concealed within the frame architecture. The braking system is enhanced with Shimano GRX parallel sub-brake levers (BL-RX812) mounted on the handlebar tops, providing secondary hydraulic access from an upright position. The rolling stock features Shimano GRX gravel-specific wheels mounted with WTB Byway TCS Light 700 x 44c tires — a slick centerline for minimized rolling resistance on pavement, transitioning to a diamond-textured shoulder for mechanical grip on loose surfaces.

The Illusion Malbec Gravel

Steel · Custom Geometry · Shimano Ultegra Di2 · FSA Carbon Wheels

The Illusion Malbec Gravel is a study in contrasts — handcrafted steel meets flagship electronics. The frame is finished in a deep Illusion Malbec powder coat that shifts from dark bordeaux to bright metallic red under changing light. Internal cable routing keeps the lines clean from headtube to dropout. The drivetrain is a Shimano Ultegra R8050 Di2 11-speed with a FSA 48/32T crankset and wide-range cassette — tight gear steps for both fast tarmac and loaded climbs. The wheel build uses FSA carbon rims with Pirelli Cinturato Gravel tyres on tan walls, combining low rolling resistance with grip on unpaved surfaces. Hydraulic disc brakes complete the setup.

High-Performance Road Build — Classified Powershift

Steel · Shimano Ultegra Di2 12-speed · Classified CF R50 Carbon Wheelset

This high-performance road build features the revolutionary Classified Powershift system integrated into a Classified CF R50 carbon wheelset, eliminating the front derailleur while maintaining a full 2x gear range. The wireless two-speed internal hub delivers instantaneous 150ms shifts — even under a full 1000-watt load — providing the aerodynamic efficiency of a 1x silhouette with the versatile gearing of a traditional setup. Seamlessly connected to a Shimano Ultegra Di2 12-speed groupset, the system is controlled directly through the electronic shifters for a clean, integrated, and cable-free cockpit experience. The 50mm deep-section carbon rims are optimized for maximum power transfer and stability, making this machine an ultra-reliable and weatherproof solution for high-speed road cycling. By merging precision electronic shifting with specialized aero engineering, this build represents the state-of-the-art in modern drivetrain technology without compromise.

The Felix Endurance

Steel · Shimano 105 R7000 2x11 · Hydraulic Disc · Fulcrum Racing 600 DB

The Felix Endurance is a performance-focused build, balancing modern speed with classic reliability. At its heart is a full Shimano 105 R7000 2x11-speed groupset, featuring a 50-34T compact crank and an 11-32T cassette to provide a versatile range for both steep climbs and fast flats. For consistent stopping power in all weather conditions, the build utilizes Shimano 105 R7070 hydraulic disc brakes. The geometry is optimized for long-distance stability, utilizing a higher stack and shorter reach to reduce spinal strain and a slacker head angle for enhanced vibration damping. The bike rolls on durable, tubeless-ready Fulcrum Racing 600 DB wheels paired with Schwalbe Pro One 28c tires, selected for their low rolling resistance and high puncture protection. To complete the build, a full Ritchey Comp finishing kit — including the stem, handlebars, and seatpost — offers an optimal balance of lightweight engineering and long-term durability.

The Magma Trekking

Steel · Rohloff Speedhub 500/14 · Gates Carbon Drive CDX · Tektro Disc Brakes

The Magma Trekking is a balanced endurance build designed for long-distance reliability. At its core, the Rohloff Speedhub 500/14 provides a 526% gear range within a sealed, weather-protected system, paired with a Gates Carbon Drive CDX for a quiet, grease-free drivetrain. The chassis features a steel fork for natural vibration damping, complemented by a classic Brooks Flyer sprung saddle for long hours on the road. Braking via Tektro MD-C550 dual-piston mechanical disc brakes — reliable and all-weather. The bike rolls on Ryde Edge rims with WTB Byway 44-622 black folding tyres and a Tubus Logo Classic rear rack for stable load carrying. A black SON 28 dynamo hub feeds a Forumslader V6 in the headtube — providing stable USB charge at any speed, with cable routing through a Cinq5 Expander. Via Bluetooth, the Forumslader logs speed, distance, altitude, gradient and battery data to a companion app (iOS/Android). Connect IQ datafield available for Garmin. GPS track recording requires a separate device.

The Ironhorse

Steel · Custom Geometry · Shimano XT 3×10 · Hope Tech Hydraulics

The Ironhorse is a heavy-duty long-distance machine with a proven track record — this exact build has covered over 10,000 kilometres across Europe and Africa. The frame features an integrated rear rack brazed directly into the steel structure, eliminating the flex and failure points of bolt-on alternatives. The drivetrain centres on a Shimano XT FC-T8000 triple crankset with a 48/36/24T configuration paired with a 10-speed 11-36T XT cassette — 30 gears covering everything from loaded Alpine passes to flat-road cruising. Shifting via Shimano XT Rapidfire Plus shifters with long-cage rear and dual-pull front derailleur. Pedals are Shimano XT SPD platform (PD-T8000) — recessed cleat for walkability, broad platform for unclipped riding. Braking is a deliberate step above standard: Hope Tech 3 E4 four-piston hydraulic disc brakes in gold anodising, paired with Hope floating 203mm rotors that actively dissipate heat on long loaded descents. Wheels are Hope 20Five rims, 32-hole tubeless-ready, on orange Hope Pro 5 hubs. The headset is a Hope EC34/28.6 in orange. Tyres are Schwalbe Marathon Mondial 700×50c — virtually puncture-proof, engineered for loaded touring across tarmac, gravel and dirt.

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The "Sakura" All-Road Trekker

Steel · Rohloff Speedhub 500/14 · Gates Carbon Drive CDX · Paul Component Engineering

A custom trekking machine built around a Rohloff Speedhub 500/14 paired with a Gates Carbon Drive CDX and Gates anodised crankset — silent, oil-free, and maintenance-free. Braking via Paul Component Engineering Touring Cantilevers mounted to Jones H-Bars. The wheelset features Ryde Andra 30 rims laced with Sapim spokes, rolling on WTB Byway 700x34 TCS tan wall tyres. Finished with Honjo fenders from Tokyo, a Tubus Logo rear rack and a Brooks Flyer saddle.

The Emerald

Steel · Custom Geometry · Shimano XT 3×10 · Hope Tech 4 E4 · British Racing Green

The Emerald is a travel-oriented expedition build for riders who cover long distances across any surface. The classic steel frame — finished in British Racing Green — is paired with a Ritchey Carbon Gravel fork for a light, responsive front end. The drivetrain is a Shimano 3×10 — Deore crankset, XT derailleurs, 11-36T cassette — wide-ranging, mechanically simple, and field-serviceable anywhere. Wheels are Hope 20Five rims on orange Hope Pro 5 hubs, with Hope Tech 4 E4 four-piston hydraulic disc brakes in orange-black and a Hope ZS44/28.6 headset carrying the orange theme through. Tyres are Schwalbe Marathon Mondial Evolution — engineered for expedition use on tarmac, gravel and rough tracks. Saddle is a Brooks B17 Special in black. British Racing Green and anodised orange — anything but understated.

Process

The Design & Engineering Process

Every Felix Cycles project starts with the complete picture — components, intended use, rider fit and finish — before a single line is drawn. Only when the full bicycle is defined can the frame geometry be optimised around it. From that specification, we develop engineering drawings through to a complete build spec ready for fabrication. Our background in frame building gives us an in-depth understanding of every stage, ensuring designs are not only technically correct but manufacturable.

Geometry Specification

Frame geometry is computed using BikeCad, a dedicated bicycle frame design application. Rider measurements — inseam, torso length, arm reach, shoulder width, and flexibility — are entered to calculate stack, reach, and standover height. These values drive key geometry parameters: head tube angle (typically 73°), seat tube angle, BB drop (e.g. 70mm), chainstay length (e.g. 410mm), and trail. The software generates a dimensioned working drawing with all tube lengths, junction angles, and axial coordinates required for jig setup and fabrication.

Tubing Specification

Our frames are constructed from nine key components: top tube, down tube, seat tube, head tube, seat stays, chain stays, fork steerer, fork blades, and bottom bracket shell. Each is sourced from Columbus' precision-engineered chromoly steel range, chosen for its consistent mechanical properties, weldability, and fatigue strength. Average tube diameters range from 25.4 mm (seat stays) to 35 mm (down tube), with wall thicknesses between 0.6 mm and 0.9 mm depending on the load path. Double- and triple-butted profiles reduce weight while maintaining rigidity at high-stress points such as the head tube junction and bottom bracket area. The bottom bracket shell is machined from oversize CrMo stock for precise alignment and long-term durability.

Mitering & Material Preparation

Tubes are cut to length and mitered using a dedicated jig and faceting tool to create precise radial profiles at each junction: seat tube to BB shell (90°), down tube and top tube to head tube, chainstays to dropouts. Dry-fit checks verify gaps below 0.5mm before any joining is performed. All tube ends are deburred and degreased with alcohol to ensure contamination-free weld interfaces. Vent holes are drilled in closed sections to prevent pressure blowout during welding.

Mechanical Fixturing

All prepared components are positioned and secured in a heavy-duty steel alignment jig. The jig maintains the exact design geometry and axial alignment throughout the joining sequence. The front triangle — BB, seat tube, down tube, top tube, and head tube — is fixtured first, followed by the rear stays. This rigid mechanical constraint is critical to prevent heat-induced distortion during welding. Initial tack welds at four points per joint lock the assembly in position before full seam welding commences.

Thermal Joining — TIG Welding

Primary structural assembly is performed by Tungsten Inert Gas (TIG) welding using ER70S-2 filler rod at 60–90A. The non-consumable tungsten electrode generates a localized arc that fuses the chromoly steel with the filler material. A stitching technique is applied to distribute heat evenly and control thermal input per joint. The welding sequence is strategically managed: front triangle first, then chainstays to BB shell, and seatstays last. Multiple passes build full weld penetration.

Brazing of Fittings

Once the main frame structure is TIG welded, smaller fittings are attached by brazing. Braze-on fittings such as bottle cage bosses, cable stops, and rack mounts are added at this stage. Brazing operates at approximately 850°C — well below the 1450°C arc temperature of TIG welding. This lower thermal input preserves the mechanical properties of the surrounding tube wall and produces a clean fillet that distributes load across the tube surface rather than concentrating it at the edge of the aperture.

Alignment Verification & Cold-Setting

Once removed from the jig, the frame is placed on a precision-ground surface plate and checked for lateral symmetry and axial alignment using plumb bobs, mandrels, and height gauges. Head tube and dropout alignment are verified against the original geometry specification. Any thermal distortion is corrected by cold-setting — the controlled application of mechanical force to bring all interfaces into perfect geometric alignment. Weld seams are ground flush and the frame surface is prepared for final machining.

Final Machining & Finishing

The frame is faced and reamed on the lathe — the bottom bracket shell is bored to thread, the head tube faced to bearing tolerance, and the seat tube reamed to precise diameter. This operation ensures all interfaces are perpendicular, concentric, and dimensionally compliant with ISO/English standards. The frame is subsequently treated with an internal anti-corrosion coating applied through the vent holes before proceeding to powder coating.

Surface Finishing & Powder Coating

The frame is blast-cleaned with glass beads to remove all surface contamination and establish a uniform anchor profile for coating adhesion. An etch/phosphate pre-treatment is applied as a conversion coating to further enhance adhesion and corrosion resistance. Colour options include complex finishes such as metallic greens and candy reds. Powder layers — base coat, metallic mid-coat, and clear top coat — are applied electrostatically and cured at 190°C for 20 minutes per layer. Decals and graphics are applied post-cure and clear-sealed for UV protection.

Final Assembly, Quality Control & Test Ride

After surface finishing, the frame enters final assembly. All interfaces are inspected and components are installed according to manufacturer specifications using calibrated torque tools. The drivetrain, braking system, and cockpit are set up and adjusted for precise operation. Cable routing, bearing preload, and fastener torque are checked systematically. Once assembly is complete, the bicycle undergoes a comprehensive quality control process, including alignment verification, shifting and braking performance, and a controlled test ride. This final validation ensures that geometry, handling and mechanical performance meet the intended design criteria before delivery.

Frame Art

Custom Painted Frames

Frame Art is a collaboration between Felix Cycles, local artists, and Oxford Bikes in Sint-Niklaas (B), sponsored by Montana — MTN. Every frame is a blank canvas: no two are alike, and no artist works the same way. Once the artwork is complete, the frame goes through the powder coating process — baked, sealed, baked again — ensuring the work stays intact for the long term. Frame Art is also part of how we build the complete picture: a deep understanding of finishes, colour, surface preparation and coating quality that feeds directly into every frame we design. The result is a bicycle that performs on the road and holds its own as a piece of art — built to the same standard as everything else we do.

The Work

Frame Art Gallery

Workshop

Repair & Preparation

We design frames and ride them — across the world. After years of frame building and thousands of kilometres in the saddle, we know what a bicycle needs to perform far from home.

Felix Cycles offers repair and maintenance for touring and trekking bikes — drivetrain overhauls, brake and gear adjustments, wheel truing and general servicing.

Before a long trip, preparation matters. We go through a standard checklist before every expedition — fresh cables, worn chain replaced, all bolts torqued, wheels trued, tyres inspected. We can prepare your bike for a bikepacking trip, or walk you through the process so you can do it yourself next time.

Flying with your bike? We pack your bicycle professionally for air transport — protected, within airline dimensions, ready to fly from Zaventem (Brussels Airport) or any other airport. We also guide you through reassembly on arrival.

Planning a tour? We offer practical advice based on long experience cycling in Europe, Africa and Asia — what to pack and how to pack it, GPX navigation and route planning, and safety on the road. No theory, just what works.

We would love to share our passion and experience with you — get in touch.

Fiets inpakken voor vliegtuig nabij Zaventem — Felix Cycles Leefdaal

Felix Cycles in Leefdaal verpakt professioneel fietsen voor luchttransport. Wij demonteren uw fiets volledig, verpakken hem veilig in een fietsdoos en zorgen dat alles klaar is voor vertrek vanuit Brussels Airport Zaventem. Ook verkrijgbaar: stevige fietsdozen te koop voor het inpakken van uw fiets voor een vliegreis.

Fiets inpakken voor vlucht vanuit Zaventem

Professioneel fiets inpakken voor vliegtuig in Leefdaal, op 10 minuten van Brussels Airport Zaventem. We hanteren de afmetingen en gewichtseisen van alle grote luchtvaartmaatschappijen: Brussels Airlines, Ryanair, TUI, KLM, Lufthansa, Transavia en meer.

Fietsdoos te koop in Leefdaal

Wij verkopen stevige kartonnen fietsdozen geschikt voor het inpakken van een fiets voor een vliegreis. De doos voldoet aan de afmetingen toegelaten door de meeste luchtvaartmaatschappijen. Ophalen in Leefdaal (Vlaams-Brabant), vlakbij Zaventem en Brussel.

Bike packing service near Brussels Airport Zaventem

Felix Cycles offers professional bicycle packing for air travel near Zaventem Brussels Airport. We disassemble, protect and box your bicycle for airline transport. Bicycle boxes for sale in Leefdaal, Belgium. We serve cyclists flying from Zaventem, Brussels, Charleroi and other Belgian airports.

Fiets verpakken vliegtuig Brussel — wat is inbegrepen

Volledig demonteren van de fiets (stuur, pedalen, derailleur, zadel)
Beschermen van kwetsbare onderdelen met schuim en folie
Verpakken in fietsdoos binnen de toegestane afmetingen
Begeleiding bij het opnieuw opbouwen van de fiets na aankomst
Fietsdozen te koop voor zelfstandig inpakken
Vertrek vanuit Zaventem (Brussels Airport), 10 minuten van Leefdaal

Fiets inpakken Zaventem · fietsdoos kopen Leefdaal · fiets verpakken vliegtuig Leefdaal · bike box Zaventem · bicycle packing Brussels Airport · fiets inpakken voor vlucht · bike packing service Leefdaal Bertem Kortenberg Tervuren

Emballage vélo pour vol depuis Zaventem — Felix Cycles Leefdaal

Felix Cycles à Leefdaal emballe professionnellement les vélos pour le transport aérien. Nous démontons votre vélo complètement, l'emballons soigneusement dans un carton à vélo et préparons tout pour votre départ depuis l'aéroport de Zaventem (Brussels Airport). Cartons à vélo disponibles à la vente à Leefdaal.

Carton vélo à vendre à Leefdaal près de Zaventem

Nous vendons des cartons solides pour l'emballage de vélos pour les voyages en avion. Le carton respecte les dimensions autorisées par la plupart des compagnies aériennes: Brussels Airlines, Ryanair, TUI fly, KLM, Lufthansa, Transavia. Retrait à Leefdaal (Brabant flamand), à 10 minutes de Brussels Airport Zaventem.

Service emballage vélo Bruxelles — ce qui est inclus

Démontage complet du vélo (guidon, pédales, dérailleur, selle)
Protection des pièces fragiles avec mousse et film
Emballage dans un carton aux dimensions autorisées par les compagnies aériennes
Accompagnement pour le remontage du vélo à l'arrivée
Cartons à vélo à vendre pour un emballage autonome
Départ depuis Zaventem (Brussels Airport), à 10 minutes de Leefdaal

Emballer vélo avion Zaventem · carton vélo Leefdaal · emballage vélo vol Bruxelles · bike box Zaventem · bicycle packing Brussels Airport · emballer vélo pour avion · service emballage vélo Leefdaal Bertem Tervuren Kortenberg Wavre

Frame Design & Engineering · Frame Building · Field Experience · Frame Art

Recent Builds