Name: Felix Cycles
Address: BE

Portfolio

Recent Builds

A selection of custom steel frames and prototype builds — each developed from geometry specification 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, engineered to withstand the most demanding conditions. The heart of the drivetrain is the legendary Rohloff Speedhub 500/14 internal gear hub, paired with the Gates Carbon Drive system for a clean, silent, and grease-free alternative to a traditional chain. To ensure reliable stopping power in any environment, the build is equipped with high-performance Shimano Deore XT hydraulic disc brakes. Off-road comfort and control are managed by a Fox Racing Shox suspension fork, while durable Schwalbe tires provide excellent grip across varied surfaces. For added comfort on rugged terrain, the bike features a Cane Creek Thudbuster suspension seatpost, which uses a patented parallel-linkage technology to effectively neutralize trail chatter and impacts. The frame is finished with a dependable Ritchey cockpit and a sleek rear rack, ensuring your gear remains secure throughout your journey.

The build is further equipped with a self-sufficient power management system built around the SON 28 Dynamo Hub. The Forumslader V6 — concealed within the frame — converts hub-generated AC power into stable DC charge via an integrated buffer battery, enabling USB charging of GPS devices and smartphones at any speed. Cable routing is managed through a Cinq5 Expander in the steerer tube, keeping the cockpit clean. A reliable, renewable power source for remote expedition use.

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 manifestation of a low-maintenance, indestructible travel machine. Its foundation is a high-grade Columbus Zona steel frame, treated with a unique process: after being bead-blasted, the frame is immediately powder-coated with a transparent varnish. This gives the bike the raw, industrial aesthetic of titanium while retaining the superior vibration-damping qualities of high-end steel. Engineered for absolute reliability, the drivetrain features a Rohloff Speedhub 500/14 paired with a Gates Carbon Drive belt. This combination eliminates the fragility of traditional derailleurs, offering a closed, oil-bath gear system and a grease-free belt that remains silent and efficient through dust, mud, and thousands of miles. For total self-sufficiency, the bike is equipped with a red SON 28 dynamo hub, which powers the high-performance SON Edelux II headlight and supplies energy to the Forumslader V6 module integrated into the headtube for charging electronics via USB. Braking power is provided by hydraulic Shimano Deore XT disc brakes. For maximum grip on unpaved paths, the bike features wide Maxxis Ikon 29 x 2.35 tires. Comfort is elevated through the Ergotec PM-705N parallel-suspension seatpost absorbing impacts at the rear. The cockpit is completed with the versatile Surly Moloko handlebar for numerous hand positions. The expedition setup is finalized with a robust Tubus Logo rear rack and the heavy-duty Surly Nice Rack at the front, offering three horizontal rails for versatile pannier positioning. Extra-wide SKS Bluemels fenders ensure this bike is fully prepared for any global journey.

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 meeting flagship electronics, classic proportions carrying modern performance. The frame and fork are finished in a deep Illusion Malbec powder coat, a colour that shifts from dark bordeaux to bright metallic red under changing light, giving the bike a visual depth that no two photographs capture the same way. Internal cable routing preserves the clean lines of the steel, with nothing to interrupt the geometry from headtube to dropout. The drivetrain is built around a Shimano Ultegra R8050 Di2 11-speed electronic groupset, delivering precise, programmable shifting under any load or gradient. Gearing is configured around a FSA 48/32T crankset paired with a wide-range climbing cassette — a 2×11 setup that keeps gear steps tight enough to maintain an efficient cadence across both fast open tarmac and demanding climbs, without the jumps of a 1× system. The steel fork provides superior vibration damping and long-term structural durability across mixed surfaces.

The wheel build centres on FSA logo-free carbon rims — stiff, aerodynamically efficient, and visually understated — delivering immediate power transfer and an aerodynamic advantage on open stretches. Mounted on these rims are Pirelli Cinturato Gravel tyres with classic tan walls, combining high puncture resistance with an optimised contact patch on unpaved surfaces. The tan wall detail ties the modern carbon and electronics back to the craft tradition of the steel frame beneath them. Hydraulic disc brakes complete the setup, providing consistent stopping power independent of mud or rain. The Illusion Malbec Gravel is technically optimised for long-distance riding where comfort, range and reliability share equal priority — a balanced machine that bridges the line between classic steelwork and modern system integration without compromise.

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 alternative to a standard chain. The chassis features a slender, lugged steel fork for natural vibration damping, complemented by a classic Brooks Flyer sprung saddle to handle long hours on the road. For consistent stopping power, the build uses Tektro MD-C550 dual-piston mechanical disc brakes, chosen for their straightforward maintenance and all-weather performance. The bike rolls on heavy-duty Ryde rims fitted with WTB Byway 44-622 black folding tires, offering a mix of tarmac speed and gravel grip. Completing the setup, a Tubus Logo Classic rear rack ensures stable handling and a low center of gravity when carrying gear.

The Magma is further equipped with a self-sufficient power management system built around the SON 28 Dynamo Hub. The Forumslader V6 — concealed within the frame — converts hub-generated AC power into stable DC charge via an integrated buffer battery, enabling USB charging of GPS devices and smartphones at any speed. Cable routing is managed through a Cinq5 Expander in the steerer tube, keeping the cockpit clean. A reliable, renewable power source for remote expedition use.

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 the roads and tracks of Europe and Africa — including the demanding roads of Uganda and the remote shores of Lake Bunyonyi (see picture). Built to absorb punishment and keep moving, the frame features an integrated indestructible rear rack brazed directly into the steel structure, eliminating the flex and failure points of bolt-on alternatives and providing a rock-solid platform for panniers under any load. The drivetrain centres on Shimano's trekking-specific groupset benchmark, built around the Shimano XT FC-T8000 triple crankset, running a 48/36/24T chainring configuration paired with a 10-speed 11-36T XT cassette — a combination that delivers an exceptionally wide gear range capable of handling both loaded Alpine passes and sustained flat-road cruising. Shifting is managed by Shimano XT Rapidfire Plus flat-bar shifters, operating a long-cage XT SGS rear derailleur and dual-pull XT front derailleur — a mechanically refined system designed specifically for the demands of multi-day trekking with uncompromising shift precision across all 30 gears. The drivetrain is completed by Shimano XT SPD platform pedals (PD-T8000), offering a recessed cleat for walkability combined with a broad platform surface for unclipped riding on technical terrain.

The braking system represents a deliberate step above the standard trekking build. Four-piston Hope Tech 3 E4 hydraulic disc brakes — finished in signature gold anodising — deliver progressive, heat-resistant stopping power under the most demanding loaded-descent conditions. Paired with Hope floating 203mm rotors on six-bolt mounts, the double-sided floating design actively dissipates heat and eliminates the brake judder common to fixed rotors on long descents. Actuation is through Hope Tech 3 flat-bar levers, providing precise hydraulic feel and full tool-free reach adjustment. The wheel build uses Hope 20Five and 20Pro rims — 20mm internal width, 32-hole, tubeless-ready touring rims — laced to hubs that match the hydraulic system's mechanical standard. Rolling stock consists of Schwalbe Marathon Mondial 700×50c tyres: a tyre engineered specifically for loaded touring across mixed surfaces, combining a high-density puncture-protection belt with a tread profile that transitions seamlessly between tarmac, gravel, and compacted dirt.

Build I — Placeholder Title

Steel · Custom Geometry · Placeholder description

Build J — Placeholder Title

Steel · Custom Geometry · Placeholder description

The "Sakura" All-Road Trekker

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

This custom-built trekking machine integrates artisanal steel craftsmanship with a zero-compromise selection of the world's most reliable components for long-distance touring. At its core, the legendary Rohloff Speedhub 500/14 internal gear hub works in tandem with the maintenance-free Gates Carbon Drive CDX system to provide a silent, oil-free drivetrain. Optimal braking performance and durability are delivered by CNC-machined Paul Component Engineering Touring Cantilevers, mounted to ergonomic Jones H-Bars for superior control across all terrains. The heavy-duty wheelset features Ryde Andra 30 rims laced with Sapim spokes, complemented by high-luster Gates anodised crankset and hand-rolled Honjo fenders from Tokyo. Equipped with an indestructible Tubus Logo rear rack and a spring-dampened Brooks Flyer saddle, this masterpiece perfectly bridges the gap between classic aesthetics and modern engineering.

The Emerald

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

The Emerald is a travel-oriented expedition build, designed for riders who cover long distances across whatever road surface presents itself. The classic steel frame — finished in one of cycling's most enduring colours — is paired with a Ritchey Carbon Gravel fork that keeps the front end light and responsive without sacrificing the long-distance compliance of the steel rear triangle. The drivetrain centres on a Shimano 3×10 system — a Deore crankset paired with XT front and rear derailleurs and an 11-36T cassette — delivering a wide enough range to handle fully-loaded climbs while keeping gear steps tight enough for efficient cadence on flat roads. The 10-speed platform was a deliberate choice: mechanically simple and field-serviceable anywhere in the world.

The wheel build pairs Hope Pro 5 hubs in signature anodised orange with Hope 20Five rims, bringing Hope's renowned engagement and sealing standard to a robust touring wheelset. Braking is handled by Hope Tech 4 E4 four-piston hydraulic disc brakes with orange-black levers, providing progressive feel and full control on loaded descents. The orange theme carries through to a Hope ZS44/28.6 headset, ensuring a play-free connection between the steel frame and carbon fork. Rolling stock consists of Schwalbe Marathon Mondial Evolution tyres — engineered for expedition use across tarmac, gravel, and rough tracks alike. Saddle comfort on long days is provided by a Brooks B17 Special in black. The result is a technically precise, visually striking machine — British Racing Green and anodised orange making a combination that is anything but understated.

How We Work

The Building Process

Every Felix Cycles frame follows a rigorous nine-stage process — from geometry specification through to powder coating and final inspection.

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.

Prototype Engineering - Bikepacking Advice and Preparation - Frame Art.

Recent Builds