The basic raw material from which NICOLAI builds their frames is aluminium, delivered as blocks and tubes. NICOLAI uses butted tubesets from EASTON® as well as aircraft grade 7020 and 7005 aluminium tubing. Milled parts which are not welded are made out of Al Cu Mg 1 aluminium.

From raw materials to a NICOLAI frame is a long way. Read on to gain a better understanding of the processes that take place to make your frame.

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The first step is the precise mitering of the tubes. In order to reduce welding distortions as much as possible, the tube must be cut exactly to fit flush against the part to which it is to be welded. A single tube can have up to four mitre cuts. Because of the large variety of different tubesets and thus the different clamps they require, this work can turn out to be quite complex and expensive. This is why NICOLAI has built a new machine specifically for this task.

All milled parts are made in-house from raw aluminium or from semi-finished extruded aluminium profiles made especially for NICOLAI. Herere too, precision has to be coupled with a high production rate. To accomplish this, we have now three CNC work stations in use: two of the most modern CNC tapping centers and a BROTHER® TC-32 A. These produce the majority of the 220 different milled parts that we use to make our frames and components.

For each model and each size frame NICOLAI has a specific welding jig on which the tubeset and milled parts are fitted together. NICOLAI's welders tack weld this assembly in precisely defined points in an exact sequence. Then, in order to minimize distortion and warping, the tubes are TIG welded together in multiple passes. Our smooth and evenly scaled welding seams are obtained through a very slow welding speed that produce a deeper penetration of the material than a spread seam. The wide and flat form of the seam provides for an optimal force distribution at the welded joint. People often ask: were these seams welded by a robot? To that NICOLAI answers "No!" All of NICOLAI's frames are welded by hand by their experienced welders. A NICOLAI frame can always be identified by its welds.

After welding, the frame is trued (straightened). Welding changes the microstructure of the aluminium and makes it softer and thus it is easier to true the frame at this point. Then the frame is put into a special oven for 14 hours for heat treating. In the oven, the microstructure of the aluminium is renewed and the material regains back most of its original stiffness.

The next step is the reaming of the upper seat tube and the drilling of the axle bores. The frame is then ready for finishing. Frames undergoing powder coating are cleaned and degreased and any ridges or scratches removed, and the frames to be anodized are bead blasted with steel beads.

After the coating process all the bearing, axle seats, and the inner surface of the head tube and the bottom bracket housing are reamed and faced on a special lathe. This ensures that all faces are parallel and true. Then the bottom bracket housing is machined to the precise dimensions and the threads are tapped.

The last step is the final assembly. A technician performs a final quality control check on all parts and any burrs or ridges are removed. Bearings and axles are then pressed in and parts are mounted on the frame. In order to ensure that your NICOLAI rides straight and true the frame is measured and exactly aligned once more. The camber and toe-in of the rear dropouts is adjusted and the disc brake mounts are also faced for a hassle free mounting of the disc brake caliper. The replaceable derailleur hanger is pinned, the correct shock for the rider’s weight fitted and the decals are put onto on the frame. After one final check and a thorough cleaning the frame moves to the shipping department where it will be assigned its final destination.

What do a Saville Row suit, a 30 kg Italian Espresso machine and a NICOLAIi frame have in common? All three are timeless products whose existence and production process exists outside the societal norms of mass-produced disposable products. NICOLAI frames are products of great value due to a creation process which is a constant quest for perfection, the skill employed in the manufacturing, and their long term durability of the frame.

Building a NICOLAI frame takes longer because NICOLAI really does take all of time necessary to acheive their goal. Give NICOLAI the time they need - you deserve a product that meets their high standards and exceeds your expectations!

NICOLAI tandem frames are available with standard or Rohloff-style rear dropouts. Frames also include cable routing that is designed to accomodate the Rohloff hub's two cable shifting system. Standard shift setup is also available.

NICOLAI tandem frames are available in anodized black, or any standard powder coat color. Anodized Silver or Bronze colors are avaiable for additional cost.

NICOLAI tandem frames are custom, and are made specifically to order. Geometry and sizing is completely customizable to the individual team, so NICOLAI can build your frame exactly how you want it!

NICOLAI  XTB Tandem Frame

MTBTandems.com Price:  $3,399.00

NICOLAI  HELIUS FS Tandem Frame

MTBTandems.com Price:  $4,499.00

Call now to order your NICOLAI... Frames are available for delivery within 6-12 weeks! 

(continental US)