Month: January 2022

Take two Mosaic frames — one Batch Built, one Made to Order — and look at them side by side. Can you tell the difference?

Probably not, and that is because our Batch Built frames go through the same made-in-USA process as any Mosaic bike that rolls out of our Boulder, Colorado shop. Here’s how we build these frames so efficiently without compromising the hand-built quality you expect from a Mosaic.

Step 1: Chain Stay Prep We offer three Batch Built models: RT-2 D for road, GT-2 AR for all-road, and GT-2 45 for gravel. As you’d expect, each model has geometry that’s optimized for its purpose. But you might not have realized that each of those three frames has a consistent chain stay length through the entire size run. This allows us to cut and weld the dropouts, chain stays, and bottom brackets in bulk so they’re prepped for the next step of the build.

Step 2: Tube Prep Next, we take seat tubes, down tubes, and top tubes and prepare them for assembly. That entails three bottle cage bosses per frame, internal brake line routing, and reinforcements for Di2 cable ports. Naturally, this stage of our Batch Built process is size-specific, and we keep each frame organized in tidy tube cubbies beneath our benches.

Step 3: Fixture Set-Up We rely on the best frame jigs in the industry, Sputnik Tool and Anvil, to ensure each frame in each size has consistent stack, reach, and angles. Now we’re getting into the fun part, when a bunch of titanium tubes start to look like a bike frame.

Step 4: Cutting and Mitering Tubes After the jig is set up to size, our framebuilders are able to see exactly how the frame’s down tube, head tube, top tube, seat tube, seat stays, and chain stay assembly will join together. It has to be a perfect fit, so in this step, they use the jig to guide the final tube cuts and mitering. Mitering? What’s that? Well, glad you asked; unless you’ve got really weird frame geometry (we don’t!), the tubes join at acute or obtuse angles. We trim the ends for a perfect fit, and also to account for the roundness of something like the head tube or bottom bracket shell. During our Batch Built process, we build several frames of the same size at once. This allows us to set up the tooling once and repeat the same precise cuts and miters over and over again until it’s time for the next size or model.

Step 5: Frame Build At last, it’s all coming together! We put all of the tubes into the fixture and start welding. However, the frame doesn’t leave the jig in a finished state. For this step of the process, our framebuilders simply tack weld the tubes. Time for another definition: Tack welding joins the tubes so the frame holds together, but it isn’t a finished, full-strength weld. This allows us to move the frame out of the fixture to our welding booth so we can get started on the next one.

Step 6: Welding Here’s where the magic happens. We take a tack-welded frame, and give it the beautiful, finished, stacked-dimes welds that will last a lifetime. Just like every Mosaic, this is all done by hand, by an expert welder.

Step 7: Quality Control In the final step of our process, each frame is thoroughly checked over to ensure that the alignment, geometry, and finish are perfect. Whether it’s a Batch Built frame or a Made to Order frame, every one gets the same attention to detail.

Final Step: You Choose Yours! By now you can probably see that every Mosaic Batch Built frame is given the same hands-on TLC as every frame we build. The best thing is that these frames are on hand, in our shop, ready to be finished for you. Once you select the model and size you want, we’ll set up the cabling to your specifications and send it to the paint and finish shop to give it any look you like.

Typically, this efficient process allows us to turn around a Batch Built frame in two weeks or less. Plus, if you end up going full-custom, our Batch Built process frees up our Made to Order queue so we can produce those frames with a quicker turnaround time.

Whichever Mosaic you choose — Batch Built or Made to Order, it is built by the same people with the same care, right here in Colorado.

Reach, stack, head tube angle, bottom bracket drop, paint, finish … You have tons of options when you order a handbuilt bike. But a while back, we started to realize that some riders don’t need a Made to Order Mosaic to get the perfect bike for their favorite rides. So, we created the Batch Built frame program to simplify things. The Batch Built program has now been expanded to include the RT-2d, GT-2 AR, GT-2 45 and MT-2.

We offer four Batch Built Models: GT-2 45, GT-2 AR, RT-2d, and our hardtail mountain bike the MT-2. Every frame is available in a standard size run from 48cm to 62cm with our tested and proven geometry. Just like every Mosaic, these frames are made by hand in our Colorado shop. Best of all, thanks to our efficient build process, Batch Built frames are available in a 1-2 week turnaround and cost $4,500 — that includes a Cane Creek headset, Columbus carbon fiber fork and standard raw finish.

So, is a Batch Built Mosaic right for you? Here’s why you might consider this option from Mosaic.

1. Simple order process. If you don’t need to spend time working out custom geometry with your bike fitter, Batch Built allows you to pick the correct size and feel confident your new bike will have perfectly balanced fit and handling.

2. Hand-built on a budget. We don’t compromise on build quality, and neither should you. We give every Batch Built frame the same attention to detail as our Made to Order frames. Thanks to our efficient process, you can get an American-made titanium frame for less.

3. Make it your own. Unlike some off-the-shelf frames, we can configure your Batch Built Mosaic for any shifting system. While the standard raw finish is the starting point for Batch Built frames, you can choose any color option you like from our paint shop to make your frame stand out. (Painted finish up-charge applies). From our experience, Batch Built checks a lot of boxes for a lot of riders. If it sounds right for you, here’s a quick guide to the three available models.

RT-2 D: Pure Road Efficiency

Reports of the road bike’s death are greatly exaggerated … Sure, we dig riding dirt, but the RT-2 D is a blast when it’s time to rack up the miles on perfect paved routes. With clearance for 30mm tires, this is a modern take on a road bike with ample comfort and traction. Most sizes have a 72.5-73-degree head tube angle for intuitive handling.

• Size range: 48-62cm
• Straight-gauge titanium tubing
• 30mm tire clearance w/ road chainline.

GT-2 AR: All Roads, Any Ride

Face it, most of us aren’t riding a Radavist-style wilderness adventure on the daily. (But if you are, congrats!) The GT-2 AR is borne out of the typical rides that help us get through the week. With clearance for 38mm tires, this bike is speedy enough for paved routes but doesn’t shy away from dirt connectors or even some sporty gravel. Most sizes have a 72-degree head tube angle for that just-right “mama bear” handling to keep you out of trouble on sketchy terrain without feeling sluggish.

• Size range: 48-62cm
• Straight-gauge titanium tubing
• 38mm tire clearance w/ road chainline.

GT-2 45: Gravel With MettleMosaic’s gravel bikes are proven at every major event from SBT GRVL to Unbound and beyond. Don’t believe it? Just ask our pro rider, Brennan Wertz, who rides our handmade titanium frames all season. Most GT-2 45 sizes sport a relaxed 71.5-degree head tube angle with a more upright riding position than the GT-2 AR for long-haul comfort. With clearance for tires as big as 48mm, this frame has the versatility for any off-pavement excursion.

• Size range: 48-62cm
• Straight-gauge titanium tubing
• 48mm tire clearance w/ gravel chainline.

Perhaps our Batch Built geometry isn’t right for your physiology. Or, you might prefer butted titanium tubes, which we use to build our top-of-the line GT-1 and RT-1 series bikes. If that’s the case, you’ll want to consider a Made to Order Mosaic frame.

We’d love to build the perfect custom frame for you.Best of all, the Batch Built program makes our shop more efficient, so Made to Order turnaround times are faster than ever at 6-8 weeks for a completely custom, Made to Order Frame.