Bicycles: Inside the Factory—Introduction (02:59)
Gregg Wallace and Cherry Healey will visit the U.K.'s largest bicycle factory and receive cycling tips from Team GB. Ruth Goodman will investigate the history of folding bikes. See Brompton Bicycle's classic folding bike.
Brompton Bicycle (06:18)
Every week, the Material Intake section receives four tons of made-to-measure parts. Wallace gathers pieces to assemble the main frame of a folding bike and receives a brazing lesson from Abdul El Said and brazes a joint.
EOS Factory (03:13)
The factory in Cardiff paints 1,000 folding bikes a week. Healey learns the process of painting bikes: steel preparation, priming, and powder coating.
Main Frame Assembly (03:25)
Wallace and Barney Fox perform a quality check before adding the frame to the manual production line. The team assembles 153 bikes a day; each bike has a "blueprint."
Road Safety (05:13)
In London, there have been 66 cycling fatalities since 2011; half involved trucks. Healey drives an HGV to better understand the challenges of keeping cyclists safe and learns where she should position herself as a cyclist. Some HGV designers added extra visibility features to lorries.
Assembly Line: Front Section (01:48)
Gary Franklin attaches the fork for the front wheel, front brake, reflector, and mud guard. CEO Will Butler-Adams oversees operations and discusses folding bikes.
Bicycle History (03:54)
Military servicemen began using folding bicycles in the 1870s; they were used in WWI and WWII. In the 1960s, folding and pack away bikes became fashionable. Harry Bickerton set the standard for folding bikes and Andrew Ritchie developed the Brompton in 1975.
Brompton Bicycle Production (03:34)
Butler-Adams explains how Ritchie's invention became a commercial product; the factory now produces 46,000 bikes a year. Wallace helps attach components as his bike continues down the assembly line.
Cycling Tips (06:02)
Cycling Coach Kevin Stewart shows Healey how small alterations in the way she rides and in her bike set up can transform her cycling experience.
Wheels and Design (02:58)
Wallace helps Rudy Usef assemble wheels for his folding bike; the rims are designed at Brompton but made off site. The wheels must withstand significant wear. The design team has to balance the bike's weight, durability, and cost.
Bicycling Pastime and Independence (04:31)
Cycling in the 19th century was mainly a male pursuit. See the Dandy Horse, the Boneshaker, the Penny-farthing, and an 1886 ladies tricycle. In the late 1880s, the invention of the safety bike improved women's cycling; the suffragettes embraced the liberation.
Last Stages of Assembly (02:38)
Wallace helps attach the wheels, handlebar, brakes, pedals, crank, and chain to his folding bike.
Bicycle Saddles (04:50)
Brooks has been making leather seats for nearly 150 years; nearly all the leather the company uses comes from the U.K. and Ireland. Wallace helps make a seat for his folding bike and attaches it back at the Brompton factory.
New Bike Designs (04:23)
Headley rides a half bike; it has no seat. New designs include: the Outrider Horizon, YikeBike, Ratracer, and electric bikes. Headley and Mike Burrows introduce the bikes to Cambridge citizens.
Bicycle Production (02:11)
Fox inspects Wallace's folding bike and approves. Brompton produces 46,000 bikes a year. Wallace reflects on his experience at the factory.
Credits: Bicycles: Inside the Factory—How Our Food Is Made (Series 2) (00:33)
Credits: Bicycles: Inside the Factory—How Our Food Is Made (Series 2)
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