Show notes
This week Randall sits down with bicycle industry pioneer, Craig Calfee. Craig has been an industry leader for decades with his work on the Calfee brand and many other collaborations throughout the industry. You cannot find someone more knowledgable about carbon (or bamboo) as a material. Calfee Designs Website Join The Ridership Support the Podcast Automated Transcription, please excuse the typos: Craig Calfee Randall [00:00:00] [00:00:04] Randall: Welcome to the gravel ride podcast. I'm your host Randall Jacobs and our guest today is Craig Calfee. Craig is the founder of Calfee Design, the innovator behind the first full carbon frames to race in the tour de France, the originator of numerous technologies adopted throughout the cycling industry, and on a personal note has been a generous and consistent supporter of my own entrepreneurial journey. I am grateful to have him as a friend, and I've been looking forward to this conversation for some time. So with that, Craig, Calfee welcome to the podcast. [00:00:32] Craig Calfee: Oh, thank you. Nice to be here. [00:00:34] Randall: So, let's start with, what's your background, give your own story in your own words. [00:00:40] Craig Calfee: Well, I've always written bikes. I mean, as a kid, that's how I got around. And that's, as you become an older child, you, uh, find your independence with moving about the world. And a bicycle of course, is the most efficient way to do that. And later on, I was a bike messenger in New York when I went to college and that kind of got me into bike design as much for the, uh, desire to make a bike that can withstand a lot of abuse. And later on, I used a bike for commuting to work at a job, building carbon fiber racing boats. And during that time I crashed my bike and needed a new frame. So I thought I'd make a frame at a carbon fiber, uh, tubing that I had been making at my. [00:01:29] Randall: my job [00:01:30] Craig Calfee: So this is back in 1987, by the way. So there wasn't a, there were no YouTube videos on how to make your own carbon bike. So I pretty much had to invent a way to build the bike out of this tubing. And at the time there were aluminum lugged bikes, and I just, I knew already aluminum and carbon fiber don't get along very well. So you have to really do a lot of things to, to accommodate that. And the existing bikes at the time were, uh, I would say experimental in the fact that they were just trying to glue aluminum to carbon and it really wasn't working. [00:02:05] So I came up with my own way and built my first bike and it turned out really well. And a lot of friends and, and bike racers who checked out the bikes that I I really should keep going with it. So I felt like I discovered carbon fiber as a, as the perfect bicycle material before anyone else. Uh, and actually, uh, right at that time, Kestrel came out with their first bike, uh, the K 1000 or something. Um, anyway that was uh, that was in 87, 88. And, uh, I felt like I should really, you know give it a go. So I moved out to California and started a bike company. [00:02:48] Randall: So just to be clear, you were actually making the tubes, you weren't buying tubes. So you're making the tubes out of the raw carbon or some pre-printed carbon. then you came up with your own way of, uh, joining those tubes. [00:03:01] Craig Calfee: Yeah. I worked on a braiding machine, so it was actually a a hundred year old, uh, shoelace braider, uh, from back in Massachusetts. There's a lot of old textile machinery braiding is, uh, you know, your braided socks and, you know, nylon rope is braided. So this is a 72 carrier braider, which means 72 spools of carbon fiber. [00:03:25] Are winding in and out braiding this tube and you just run it back and forth through this braider a few times. And now you have a thick enough wall to, uh, I developed a and tape wrapping method at that job and came up with a pretty decent way to make a bicycle tube. So that was kind of the beginning of that. [00:03:47] Uh, and since then I've explored all kinds of methods for making tubing, mainly through subcontractors who specialize in things like filament winding and roll wrapping. And, uh, pultrusion, you know, all kinds of ways to make tubing. And that does relate to kind of an inspiration for me, where I realized that, uh, carbon fiber, you know, high performance composites are relatively young and new in the world of technology where metals are, you know, the metals have been around since the bronze age. [00:04:21] I mean, literally 5,000 years of development happened with metals, carbon fiber, uh, high-performance composites have only really been around since world war two. So that's a huge gap in development that hasn't happened with composites. So that to me felt like, oh, there's some job security for a guy who likes to invent things. So that was my, a kind of full force to get me to really focus on composite materials. [00:04:51] Randall: Were you that insightful in terms of the historical context at the time, or is that kind of a retro or retrospective reflection? [00:04:58] Craig Calfee: I think, I don't know. I think I may have read about that. Um, I a friend who had a library card at MIT and I pretty much lived there for a few weeks every, uh, master's thesis and PhD thesis on bicycles that they had in their library. And I think somewhere in there was a, uh, a topic on composites and comparing the technology of composites. [00:05:23] So. I probably that from some reading I did, or maybe I did invent that out of thin air. I don't remember, uh, nonetheless, uh, the fact of it is, you know, not, not a whole lot of mental energy has been put into coming up with ways of processing fiber and resin compared to metal. So to me that just opens up a wide world of, of innovation. [00:05:49] Randall: Um, and so the first frame was that, um, you're creating essentially uniform tubes and then mitering them, joining them, wrapping them as you do with your current bamboo frames or what was happening there. [00:06:02] Craig Calfee: Uh, it's more like the, uh, our, our carbon fiber frames were laminating carbon fabric in metal dyes, and those are not mitered tubes fitting into the dyes. And that's, that's a process. I got my first patent on. And it, uh, so in the process of compressing the carbon fabric against the tubes, you're you end up with these gussets in what is traditionally the parting line of a mold and rather than trim them off completely. [00:06:31] I, I use them as reinforcing ribs. [00:06:35] Randall: Yep. Okay. So that explains the, the, that distinctive element that continues with your, um, some of your, uh, to tube, uh, currently [00:06:48] Craig Calfee: them [00:06:49] the hand wrapping technique from that you currently see on the bamboo bikes came from developing a tandem frame, or basically a frame whose production numbers don't justify the tooling costs. Um, so that's hand wrapped. That's just literally lashed to. Yeah. And a point of note, there is I was a boy scout growing up and, uh, there's this merit badge called pioneering merit badge. [00:07:16] And I really enjoyed pioneering merit badge because it involved lashing row, uh, poles together with rope and the pro you had to do with this one project. And I did a tower and it was this enormous structure that went just straight up like a flagpole, but it was it involved a bunch of tetrahedrons, uh, stacked on top of each other and lashed together. [00:07:41] you know, culminating in a pole that went up. I don't remember how tall it was, but it was, it was really impressive. And everybody, you know, thought, wow, this is incredible of poles and some rope. And here we have this massive tower. So anyway, I was into things together since a young age. [00:08:00] And so I immediately came up with the, uh, the last tube concept. Which is where the, now the bamboo bikes are. course there's a specific pattern to the wrapping, but, um, the concept is basically using fiber to lash stuff together, [00:08:16] Randall: When it immediately brings to mind, what's possible with current generation of additive production techniques. Uh, whereas before you could make small components and then lash them together to create structures that otherwise aren't manufacturable. [00:08:31] Now you'd be able to say, print it out though. Those, you know, those printed out materials don't have the performance characteristics of a, you know, a uni directional carbon of the sword that you're working with currently. [00:08:42] Craig Calfee: right? [00:08:43] Randall: Um, so we've gone deep nerd here. We're going to, I'm going to pull us out and say, okay, uh, lots of time for this. [00:08:49] This is going to be a double episode. Uh, so next up, let's talk about those frames, uh, saw their big debut. [00:08:59] Craig Calfee: Yeah. So, um, we started making custom geometry for a. In 1989 and selling them and so big and tall, and that the idea of custom geometry frames was, uh, you know, pretty esoteric. And the pro racers were, we're using a lot of custom frames. So Greg Lamond, uh, was in search of a carbon fiber, uh, custom frame builder in, uh, 1990. [00:09:31] And, uh, no one really was doing it. We were literally the only company making custom carbon frame bikes. So he, uh, found out about us, uh, effectively discovered us, shall we say? And, uh, it didn't take long for him to order up 18 of them for his, his, uh, team Z, uh, teammates. He was sponsoring his own team with a Lamont brand. [00:09:56] So we didn't have to sponsor him. He basically paid for the frame. Put his name on them. And, and, uh, now we're now we're on the defending champions, a tour de France team. So that was a huge break obviously. And it was really a pleasure working with Greg and getting to know the demands of the pro Peloton, uh, you know, that really launched us. [00:10:21] So that was, uh, quite a splash. And, you know, it always is a great answer to the question. Oh, so who rides your bike kind of thing. you know, you have the, the full-on best one in the world at the time. So, so that was a fun thing. [00:10:39] Randall: And the name of the company at the time was, [00:10:41] Craig Calfee: Uh, carbon frames. [00:10:42] Randall: yeah. So anyone wanting [00:10:45] dig up the historical record, [00:10:47] Craig Calfee: is this too generic? You know, the other to what you're talking about, the adventure bikes. Yeah, we had to stop. I mean, carbon frames is a terrible name because everyone started talking about all carbon fiber frames as carbon frames. So we thought that was cool, you know, like Kleenex, you know, uh, and then we came up with the adventure bike, you know, with very early, uh, adventure bike. [00:11:11] And it was just, we called it the adventure bike. And now there's a classification called adventure bikes that, you know, so, um, I think we, we, we went too generic on how we named our models. [00:11:26] Randall: I've drawn from the rich tradition, a tradition of Greek, you know, uh, philosophy for naming my own companies in the like, [00:11:35] Craig Calfee: Yeah. [00:11:36] Randall: uh, um, and then next up, uh, so you've worked with Greg Lamond on those frames. Carbon frames is up and running and you're, you're producing custom geo frames and you're starting to get at some scale at this point and some notoriety. [00:11:52] next up you were working on your bamboo bikes. When we talk about that [00:11:57] Craig Calfee: Yeah, that was say, I'm kind of at the, at the time, it was just a way to get publicity. So at the Interbike trade show, you'd have a few creative people making some wacky bikes out of beer cans or, or other just weird things just to get attention, just, just to send the media over to your booth, to take a picture of some wacky thing that you're doing. [00:12:20] yeah, we got to do something like that to get, get some attention. And the, uh, so I was looking around for some PVC pipe. Maybe I was going to do a PVC pipe bike, and I wasn't really sure, but I knew that we could just wrap any tube. Make a bike out of literally anything. So, um, my dog was playing with some bamboo behind the shop. [00:12:42] Uh, she was a stick dog, so she loved to clamp onto a stick and you could swing her around by the, by the sticks. She's a pit bull and lab mix. Anyway, we ran out of sticks. Uh, cause we only had one little tree in the back, but we did have some bamboos. So she came up with a piece of bamboo and I was her around by it, expecting it to break off in her mouth because I just wasn't aware of how strong bamboo was, but it turned out it was really quite strong. [00:13:12] And I said, oh, let's make a bike out of this stuff. And sure enough, uh, the bike was, uh, quite a attention getter. It got the quarter page and bicycling magazine so that, you know mission accomplished on that front. And, but the bike itself rode really well. [00:13:29] Randall: well [00:13:30] Craig Calfee: Um, when I wrote my first carbon bike, uh, the very first ride on my very first carbon bike, I was struck by how smooth it was. [00:13:38] It had this vibration damping that was, you know, just super noticeable and, and that really kind of lit a fire under my butt thinking, wow, this is really cool. When I built my first bamboo bike, I had that same feeling again, how smooth It was It was amazing for its vibration damping. So, uh, I knew I was onto something at that point. [00:14:02] Uh, that first bike was a little too flexy, but, uh, the second bike I built was significantly stiffer and was an actual, real rideable bike. So, uh, from that point, uh, we just started building a few here and there and it was still a novelty item until about, uh, 1999, 2000. When a few people who had been riding them, or like, I want another one, I I want to know mountain bike this time. [00:14:29] So as it was just starting to get known and, uh, we started selling them through dealers. And I mean there's a lot of stories I can tell on how that evolved and how people started actually believing that a bamboo bike could actually exist in the world. So it took a while though. [00:14:49] Randall: I think there's a whole thread that we could tug on maybe in a subsequent episode where we focus just on the bamboo bike revolution. [00:14:57] Craig Calfee: Yeah. Yeah. That's um, there's a lot of, lot of stuff going on there. I'm actually writing my second book on history of the bamboo bike, because there's so many interesting angles to it, particularly in the. [00:15:10] Randall: in Africa [00:15:12] I'm struck by the juxtaposition of this bleeding edge. Uh, you know, high-tech material that you pioneered and then this going back to one of the most basic building materials, uh, that we have building bikes out of that. And in fact, um, on the one hand, there's this, this extreme, know, difference in terms of the technology ization of each material. [00:15:34] But on the other hand, there's a parallel the sense that like carbon, in tubes is best, uh, you know, generally, uh, when it's you need to write. Yeah, with maybe some cross fibers in order to prevent, prevent it from separating. And bamboo also has that characteristic of having, you know, you need directional fibers that are bonded together by some, uh, you know, some other material in, in the, in the bamboo [00:15:58] Craig Calfee: Yeah. Yeah, it's very, there's a lot of similarities. I mean, bamboo is amazing just because it grows out of the ground and tubular for. And it grows a new, huge variety of diameters and wealth thicknesses. So if you're looking for tubing, I mean, you don…
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