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- ♪ MTV
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00:00:04,520 --> 00:00:06,320
- Every year,
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00:00:06,360 --> 00:00:09,480
people in Britain cycle
more than three billion miles,
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00:00:09,560 --> 00:00:12,560
and over half of us
own a bicycle.
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00:00:12,600 --> 00:00:16,120
- We buy over 3 1/2 million
of them every year.
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00:00:16,160 --> 00:00:19,160
[upbeat music]
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- But what engineering skills
does it take to build a bike
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00:00:22,240 --> 00:00:24,160
and get it on the road?
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We've come to the UK's largest
bicycle factory to find out.
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[Gregg laughing]
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I'm Gregg Wallace.
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Wheels!
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And I'll be joining
this multi-stage
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00:00:35,320 --> 00:00:38,400
manual production line
to make my own bike.
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- There's just
over 16 1/2 million
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00:00:40,760 --> 00:00:41,680
different combinations.
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- Don't be ridiculous.
18
00:00:43,320 --> 00:00:46,280
Learning skills
that take years to master.
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- You're holding 1,000 degrees
in your hand.
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00:00:48,400 --> 00:00:49,720
[Gregg groaning]
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- And trying to keep up
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with their 24-hour
production targets.
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I'm sorry.
I was chatting, I'm sorry.
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Let's go, let's go!
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- I'm Cherry Healey.
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I'll be learning the secrets
of painting a bike
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00:01:01,600 --> 00:01:03,480
fit for the British weather.
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You bake it in an oven!
29
00:01:06,000 --> 00:01:08,600
- Historian Ruth Goodman
investigates the role
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00:01:08,640 --> 00:01:11,400
bikes played
in the D-day landings.
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- This seems an enormously
heavy machine to be wearing
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00:01:13,320 --> 00:01:15,440
whilst you jump out of a plane
in a parachute.
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- And how two wheels helped
women fight for equality.
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- The bicycle really was, then,
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a part of the sort of tools
of the trade
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00:01:22,600 --> 00:01:24,440
in their political ambitions.
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[upbeat music]
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- A brand-new bicycle
comes off this production line
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every 3 1/2 minutes.
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- Hey!
- Ta-da!
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And we're going to show you
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the amazing engineering
and craftsmanship
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that goes
into making every single one.
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Welcome
to "Inside the Factory."
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- [bicycle wheel whirring]
- [wrench cranking]
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[conveyor belt whirring]
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[machinery humming]
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♪ ♪
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[cereal clattering]
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♪
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- Welcome to the Brompton
Bicycle factory in West London.
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It's the largest bike factory
in Britain.
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- This is their
classic folding bike
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00:02:08,720 --> 00:02:12,240
and it can be unfolded
in as little as six seconds.
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- Over 1,000 of these a week
roll out of this factory,
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ready to be shipped
around the world.
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- Nearly got it. Ah!
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- Do you need a tiny bit
of help there?
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Let's have a go.
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♪
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- [laughs] Thank you, Cherry.
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That's a clever design
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but quite complicated
to manufacture.
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- They start off life like
this, 1,200 individual parts.
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- Tonight, we're gonna show you
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how a team of hundreds
can turn this
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00:02:48,200 --> 00:02:51,440
into a working bicycle
in less than 24 hours.
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[upbeat music]
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This is the largest company
manufacturing bikes in the UK.
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00:03:00,000 --> 00:03:03,880
And they hand-build every
frame.
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All the raw steel they use
comes from Spain
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00:03:05,920 --> 00:03:07,560
in six-meter lengths,
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so first, it goes
to a specialist company
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00:03:09,720 --> 00:03:12,800
in Leicester to be laser-sliced
or machine-sawed.
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[metal clanking]
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♪
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At the London bicycle factory,
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the material intake section
receives four tons
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of made-to-measure parts
every week.
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00:03:25,240 --> 00:03:28,680
That's enough
for more than 150 folding bikes
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00:03:28,720 --> 00:03:31,600
every 24 hours of production.
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And I'll be responsible
for one of them.
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The countdown from metal bits
to my bicycle begins.
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I'm going to need
a lot of help,
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starting with training manager,
Barney Fox.
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00:03:45,880 --> 00:03:47,320
- Are you gonna give me my
bits? - Absolutely.
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First of all,
I think we should start
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00:03:48,440 --> 00:03:50,040
with the main frame.
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00:03:50,080 --> 00:03:52,160
Two bits of tubing for you.
Take one of those.
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00:03:52,200 --> 00:03:53,440
That's where your bottom
bracket will go.
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00:03:53,480 --> 00:03:54,920
That's where your crank
and chain set go.
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00:03:55,000 --> 00:03:56,520
Main frame tubing.
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00:03:56,560 --> 00:03:58,840
All right,
couple of chainstays for you,
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00:03:58,880 --> 00:04:00,800
left and right.
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00:04:00,840 --> 00:04:03,120
So, you can take that as well.
Gonna need a handlebar stem.
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00:04:03,160 --> 00:04:05,960
- Are you sure
this actually makes a bike?
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00:04:06,000 --> 00:04:08,840
- You're also going to need
a fork to be able to...
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00:04:08,920 --> 00:04:09,920
[metal clanging]
99
00:04:09,960 --> 00:04:12,480
- Well.
- Sorry, Barney.
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00:04:12,520 --> 00:04:14,000
- There you are.
101
00:04:14,040 --> 00:04:15,800
Keep hold of that.
Where can I put that?
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00:04:15,840 --> 00:04:17,600
Then to finish off
the main frame,
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00:04:17,680 --> 00:04:19,840
put in a seat tubing in there.
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00:04:19,920 --> 00:04:21,720
There's a little bit more
than I thought there'd be.
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Is it starting to look
like a bike yet?
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00:04:23,600 --> 00:04:25,000
- Not at all.
- [Barney laughs]
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- I feel like the Tin Man.
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That's not a bike, surely!
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00:04:28,360 --> 00:04:30,880
[upbeat music]
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33 separate pieces of metal
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00:04:33,440 --> 00:04:35,720
will form the skeleton
of my bike
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00:04:35,800 --> 00:04:37,920
and every single part
will be joined together
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00:04:37,960 --> 00:04:42,120
not by robots, but by artisans.
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00:04:42,160 --> 00:04:43,960
First out of my box of bits,
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it's the biggest tube
in the main frame.
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It needs bending
into its distinctive shape
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00:04:50,320 --> 00:04:52,800
and they do that
with the original mold press,
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designed more than 30 years
ago.
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♪
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That machine is set to do this
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at the right angle
every time, is it?
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00:05:00,760 --> 00:05:01,840
- Yes.
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00:05:01,880 --> 00:05:03,720
- Where does this bit go? Up?
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00:05:03,760 --> 00:05:05,920
- Over here.
- Like that?
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00:05:05,960 --> 00:05:09,400
It's shaped every folding bike
that's left this factory,
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00:05:09,440 --> 00:05:13,440
using a pressure five times
the weight of a white rhino.
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00:05:13,480 --> 00:05:17,960
And now, is this that bit?
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00:05:18,000 --> 00:05:19,480
No, it's not that bit.
129
00:05:19,520 --> 00:05:22,240
If you turn it out,
it will be this way.
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00:05:22,280 --> 00:05:23,760
- So, that's...
131
00:05:23,800 --> 00:05:26,760
- Yes.
- That bit.
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00:05:26,800 --> 00:05:28,920
Just 15 minutes
after the raw steel
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arrived at the factory,
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00:05:30,720 --> 00:05:33,120
and I've now got all the parts
of my frame ready.
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00:05:33,200 --> 00:05:36,120
Now it's time to start turning
it into a bike.
136
00:05:36,160 --> 00:05:37,320
- Thank you.
137
00:05:37,360 --> 00:05:40,040
[upbeat dance music]
138
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The 33 steel parts of the frame
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need joining together
by brazing.
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00:05:47,360 --> 00:05:48,720
It's like soldering
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00:05:48,760 --> 00:05:53,960
but at an extreme heat
of 1,000 degrees.
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00:05:54,000 --> 00:05:56,560
It's all done by hand.
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00:05:56,640 --> 00:05:58,200
There are 42 braziers
144
00:05:58,240 --> 00:06:01,600
and the most experienced
is Abdul el-Zahidi.
145
00:06:01,640 --> 00:06:03,600
- Hello!
- Hello, Gregg.
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00:06:03,640 --> 00:06:06,040
- He's worked here for 18
years.
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00:06:06,080 --> 00:06:07,560
What is your role here, Abdul?
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00:06:07,600 --> 00:06:09,840
- I train every single person
in here
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00:06:09,880 --> 00:06:11,440
how to become brazier.
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00:06:11,480 --> 00:06:13,920
- Right.
151
00:06:13,960 --> 00:06:17,160
Training takes 18 months and,
after qualifying,
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00:06:17,200 --> 00:06:20,520
each brazier is allowed
to sign their own work.
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00:06:20,600 --> 00:06:22,400
They stamp their own initials?
154
00:06:22,440 --> 00:06:25,280
- Every single brazier,
he does have his own initial.
155
00:06:25,320 --> 00:06:26,960
These bikes
are going all over the world
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00:06:27,000 --> 00:06:28,720
and it's got one of your boys'
initials on it?
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00:06:28,760 --> 00:06:31,720
- Exactly.
158
00:06:31,760 --> 00:06:34,520
- The wall of fame
shows the pride in their work
159
00:06:34,560 --> 00:06:36,760
and I'm hoping
I can live up to the legacy
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00:06:36,800 --> 00:06:39,600
as Abdul's latest trainee.
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00:06:39,640 --> 00:06:42,000
- 'Cause a sleeve
is extra protection.
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00:06:42,040 --> 00:06:44,120
You're holding 1,000 degree
in your hand.
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00:06:44,160 --> 00:06:46,120
- You're kidding me.
164
00:06:46,160 --> 00:06:48,240
That's the melting point
of bronze,
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which forms an incredibly
strong and solid bond
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00:06:51,200 --> 00:06:53,040
between the joints.
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00:06:53,080 --> 00:06:54,680
When was the last time
you burnt yourself?
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00:06:54,720 --> 00:06:57,400
- Maybe three months ago.
169
00:06:57,440 --> 00:06:59,440
- Oh, no, Abdul!
- Little touch with the--
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00:06:59,480 --> 00:07:00,800
it's only a little touch.
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00:07:00,840 --> 00:07:02,240
♪
172
00:07:02,280 --> 00:07:04,600
- I'm right out
of my comfort zone.
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00:07:04,640 --> 00:07:06,560
- Ah-ha.
- Very safe, very safe.
174
00:07:06,600 --> 00:07:08,560
Nothing to worry.
Like a pen in your hand.
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00:07:08,600 --> 00:07:11,360
Right, what we're going to do,
the wire in this hand
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00:07:11,400 --> 00:07:13,200
and I'll show you
how simple and easy
177
00:07:13,280 --> 00:07:14,480
and you're going to love it.
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00:07:14,560 --> 00:07:15,720
- [metal clinking]
- Oh, yeah.
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00:07:15,800 --> 00:07:16,840
- Don't worry.
Like everyone.
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00:07:16,880 --> 00:07:18,640
- I'm not at all nervous.
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00:07:18,680 --> 00:07:20,920
♪
182
00:07:20,960 --> 00:07:24,720
- Slowly. Excellent.
Keep going with the torch.
183
00:07:24,760 --> 00:07:26,200
Excellent, that's the one.
184
00:07:26,240 --> 00:07:28,800
So, you're wishing
to become a master brazier?
185
00:07:28,840 --> 00:07:30,320
- Well, I tell you what,
186
00:07:30,400 --> 00:07:32,480
I would be tired
at the end of the day
187
00:07:32,520 --> 00:07:34,240
because this is quite
precise work.
188
00:07:34,280 --> 00:07:35,680
- Very good, go.
189
00:07:35,720 --> 00:07:37,120
- If that's melting
metal together,
190
00:07:37,200 --> 00:07:40,760
that would make
a terrible mess of my fingers.
191
00:07:40,800 --> 00:07:43,280
Now I've practiced,
Abdul's letting me braze
192
00:07:43,320 --> 00:07:46,200
one of the joints on the bike
I'm building,
193
00:07:46,240 --> 00:07:50,720
under his watchful eye
and, well, safe in his arms.
194
00:07:50,800 --> 00:07:53,960
- 90-degree, like that.
195
00:07:54,000 --> 00:07:55,600
So what we do,
196
00:07:55,640 --> 00:07:56,760
we heat that little bit
in a straight line,
197
00:07:56,840 --> 00:07:57,880
little bit.
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00:07:57,920 --> 00:07:59,920
♪ My darling
199
00:07:59,960 --> 00:08:03,680
Into where it glows,
soon it join together.
200
00:08:03,720 --> 00:08:08,200
♪ For your touch
201
00:08:08,240 --> 00:08:11,000
I'm going to leave you
to continue on your own.
202
00:08:11,040 --> 00:08:13,360
- You can't leave me!
- Well done. Very good.
203
00:08:13,400 --> 00:08:16,640
♪ I need
204
00:08:16,680 --> 00:08:18,120
I'll break it.
205
00:08:18,160 --> 00:08:19,960
♪ Your love
206
00:08:20,040 --> 00:08:21,640
♪ ♪
207
00:08:21,680 --> 00:08:23,000
Not bad,
208
00:08:23,080 --> 00:08:25,920
but nowhere near
as good as these guys.
209
00:08:25,960 --> 00:08:28,400
Can I take one of yours?
Is that okay?
210
00:08:30,280 --> 00:08:31,600
Abdul!
211
00:08:31,640 --> 00:08:32,640
- Yes, mate?
- I've finished.
212
00:08:32,680 --> 00:08:33,800
- Well done.
213
00:08:33,880 --> 00:08:35,080
- What do you think?
214
00:08:35,160 --> 00:08:37,200
- Wow, fantastic!
215
00:08:37,240 --> 00:08:39,400
- Not bad, huh?
- Professional. Very good.
216
00:08:39,440 --> 00:08:40,720
- Actually--
- Is that the one you brazed?
217
00:08:40,760 --> 00:08:42,360
- No, actually. [laughing]
218
00:08:42,440 --> 00:08:45,200
I thought that looked okay
until I saw my friend's.
219
00:08:45,240 --> 00:08:46,600
- The more we practice,
220
00:08:46,680 --> 00:08:48,040
the more you get better
and better.
221
00:08:48,080 --> 00:08:49,760
I don't deserve to be here,
222
00:08:49,800 --> 00:08:53,280
but I made it
to the wall of fame.
223
00:08:53,320 --> 00:08:56,080
And luckily, Abdul's team
is giving me a hand,
224
00:08:56,120 --> 00:08:58,160
brazing
the rest of my bike joints,
225
00:08:58,200 --> 00:09:02,760
normally
an intensive four-hour job.
226
00:09:02,800 --> 00:09:04,160
There you go.
227
00:09:04,200 --> 00:09:05,640
With a little bit of help
from Abdul,
228
00:09:05,680 --> 00:09:07,920
I've finished the parts
of my bike frame
229
00:09:07,960 --> 00:09:09,400
and now they're gonna go off
and get painted.
230
00:09:12,040 --> 00:09:14,720
[upbeat pop-rock music]
231
00:09:14,760 --> 00:09:18,600
My bike frame leaves London
to travel 150 miles
232
00:09:18,640 --> 00:09:20,280
to a factory in Cardiff,
233
00:09:20,320 --> 00:09:24,040
where they paint
1,000 folding bikes a week,
234
00:09:24,080 --> 00:09:26,880
and Cherry's in charge
of my paint job.
235
00:09:26,920 --> 00:09:28,920
- So when you order your bike,
236
00:09:28,960 --> 00:09:33,200
you can choose from over 100
different color combinations
237
00:09:33,280 --> 00:09:37,120
and every single bike
comes through this one factory,
238
00:09:37,160 --> 00:09:39,200
here in Cardiff, to be painted.
239
00:09:39,240 --> 00:09:41,000
I suppose
I'd better get cracking then.
240
00:09:41,040 --> 00:09:42,960
[upbeat pop-rock music]
241
00:09:43,000 --> 00:09:47,040
First, we're dipping the parts
into a series of 11 giant
baths,
242
00:09:47,120 --> 00:09:49,880
and that's just to prepare
the steel for painting.
243
00:09:49,960 --> 00:09:54,080
Have a nice bath!
244
00:09:54,120 --> 00:09:56,080
In the 2 1/2-hour process,
245
00:09:56,120 --> 00:10:00,200
the frame gets
an alkaline wash to clean it,
246
00:10:00,240 --> 00:10:03,040
a coating of crystals
to protect it from rust,
247
00:10:03,080 --> 00:10:05,880
and it's dunked in a bath
of base paint
248
00:10:05,920 --> 00:10:09,720
with an electric charge
to make it stick to the metal.
249
00:10:09,800 --> 00:10:12,600
The manager here
is David Morgan.
250
00:10:12,640 --> 00:10:14,400
Do you have to do this
with normal bikes?
251
00:10:14,440 --> 00:10:17,000
It sounds extremely
labor-intensive.
252
00:10:17,080 --> 00:10:19,120
The importance of this,
with a folding bike,
253
00:10:19,160 --> 00:10:20,960
is that when you open the bike,
254
00:10:21,000 --> 00:10:23,640
you're opening the bike
to the elements, effectively.
255
00:10:23,680 --> 00:10:26,080
So, if the inside of the bike
isn't protected,
256
00:10:26,160 --> 00:10:27,920
the inside of the bike will
rust
257
00:10:27,960 --> 00:10:29,720
and the bike will effectively
rust from the inside out.
258
00:10:29,760 --> 00:10:32,600
- Is that really the only way
to get that protection?
259
00:10:32,680 --> 00:10:34,080
- If you want a premium finish,
yes.
260
00:10:34,120 --> 00:10:36,800
- If only Gregg knew
how much hard work
261
00:10:36,840 --> 00:10:39,480
goes into just priming
the frame.
262
00:10:39,520 --> 00:10:42,040
You're not even painting it
yet! - Nope.
263
00:10:42,080 --> 00:10:43,080
[upbeat music]
264
00:10:43,120 --> 00:10:44,680
- Before we can start,
265
00:10:44,760 --> 00:10:47,840
Gregg's bike frame is heated
for 45 minutes
266
00:10:47,880 --> 00:10:52,320
at 180 degrees
to harden the primer.
267
00:10:52,360 --> 00:10:55,200
At last, overalls on, I'm
ready.
268
00:10:55,240 --> 00:10:57,120
[Cherry grunts]
269
00:10:57,160 --> 00:10:59,960
Showing me how to do
a professional paint job
270
00:11:00,000 --> 00:11:02,280
is managing director
Steve Rosher.
271
00:11:02,320 --> 00:11:03,760
Can I have a paintbrush?
272
00:11:03,800 --> 00:11:05,120
- No.
273
00:11:05,160 --> 00:11:07,360
What you need
is a powder coating gun.
274
00:11:07,400 --> 00:11:09,040
- A powder coating gun?
275
00:11:09,080 --> 00:11:10,560
Surely if you put powder
onto metal,
276
00:11:10,600 --> 00:11:12,120
it will just blow off.
277
00:11:12,160 --> 00:11:15,440
- Not if you use
the proper equipment.
278
00:11:15,480 --> 00:11:18,400
- The paint powder
is electrostatically charged,
279
00:11:18,440 --> 00:11:21,360
so it's attracted
to every little bit
280
00:11:21,400 --> 00:11:25,000
of the steel surface.
281
00:11:25,040 --> 00:11:26,960
That looks painted to me.
282
00:11:27,000 --> 00:11:28,800
That looks
like a painted piece of metal.
283
00:11:28,840 --> 00:11:30,240
- Okay, but at the moment
284
00:11:30,280 --> 00:11:33,040
it's held
on just by static electricity,
285
00:11:33,080 --> 00:11:34,080
so if you touch it--
286
00:11:34,160 --> 00:11:36,560
- Whoa!
- It comes away.
287
00:11:36,600 --> 00:11:38,040
- What?
- So, it's still a dry powder.
288
00:11:40,560 --> 00:11:42,920
Wow! Amazing!
289
00:11:43,000 --> 00:11:44,520
It just falls off.
290
00:11:44,560 --> 00:11:45,840
Obviously,
you can't send this bike
291
00:11:45,880 --> 00:11:47,360
out for someone to ride
292
00:11:47,400 --> 00:11:49,280
'cause it would come off
in one rain shower.
293
00:11:49,320 --> 00:11:50,640
- So we have to bake it
in an oven.
294
00:11:50,680 --> 00:11:53,280
- You bake it in an oven?
295
00:11:53,320 --> 00:11:55,080
But before that happens,
296
00:11:55,120 --> 00:11:58,320
I need to get
Gregg's frame painted.
297
00:11:58,360 --> 00:12:00,240
Ta-da!
298
00:12:00,320 --> 00:12:01,800
- Well done.
299
00:12:01,840 --> 00:12:03,240
Job looks good.
300
00:12:03,280 --> 00:12:06,000
- Shall we put them in the
oven? - Yes!
301
00:12:06,040 --> 00:12:09,480
After baking for 15 minutes
at 180 degrees,
302
00:12:09,520 --> 00:12:11,880
the parts are ready.
303
00:12:11,960 --> 00:12:13,800
- So, it goes off down
to quality control now,
304
00:12:13,840 --> 00:12:16,040
and then it's up to London,
back to Gregg.
305
00:12:16,080 --> 00:12:17,680
♪
306
00:12:17,760 --> 00:12:21,720
- This bike has been primed,
painted, and baked
307
00:12:21,800 --> 00:12:23,240
and now I look like a Smurf!
308
00:12:25,000 --> 00:12:26,600
- Back at the factory,
309
00:12:26,640 --> 00:12:29,600
and we're now 16 hours
into building my bike.
310
00:12:29,640 --> 00:12:31,240
I've got my hands
on my frame again
311
00:12:31,280 --> 00:12:33,560
and now it's looking fabulous.
312
00:12:33,640 --> 00:12:37,400
[upbeat rock music]
313
00:12:37,440 --> 00:12:41,120
My bike parts will pass through
a 28-person production line.
314
00:12:43,320 --> 00:12:47,040
The 12 most time-critical jobs
on the main assembly
315
00:12:47,080 --> 00:12:50,920
have just 3 1/2 minutes
before the bike moves on.
316
00:12:51,000 --> 00:12:54,840
♪ ♪
317
00:12:54,880 --> 00:12:59,400
And the target board
keeps everyone on track.
318
00:12:59,440 --> 00:13:03,160
They build 153 bikes a day
319
00:13:03,200 --> 00:13:06,360
and each one can be
completely different.
320
00:13:06,400 --> 00:13:08,880
There's just over 60 1/2
million different combinations.
321
00:13:08,960 --> 00:13:10,520
- Don't be ridiculous.
- Absolutely.
322
00:13:10,560 --> 00:13:12,920
- How?
Forgive me, but how?
323
00:13:12,960 --> 00:13:14,480
- We can have
lots of different colors,
324
00:13:14,520 --> 00:13:17,240
different types of handlebars,
different gear rangings,
325
00:13:17,280 --> 00:13:18,960
you can have mudguards,
326
00:13:19,000 --> 00:13:21,440
you don't have
to have mudguards.
327
00:13:21,520 --> 00:13:24,080
- Before I can get
going with my bike,
328
00:13:24,120 --> 00:13:26,720
I've got to find the beginning
of the assembly line.
329
00:13:26,800 --> 00:13:28,400
Someone's gotta help me.
330
00:13:28,440 --> 00:13:31,560
I've gotta put a bike together,
where do I start?
331
00:13:31,600 --> 00:13:33,240
- Maybe over there.
- Start over there?
332
00:13:33,320 --> 00:13:35,960
- Very good.
- I need help!
333
00:13:36,000 --> 00:13:37,400
Are you the first bit?
I'm Gregg.
334
00:13:37,440 --> 00:13:39,240
- I'm Rafal.
335
00:13:39,280 --> 00:13:41,000
- In the main frame station
one,
336
00:13:41,040 --> 00:13:42,920
16 hours and eight minutes
after
337
00:13:42,960 --> 00:13:45,280
they were plain metal tubes,
338
00:13:45,360 --> 00:13:48,240
Rafal Sekovski will start
connecting them together.
339
00:13:48,280 --> 00:13:50,840
What is this bit? What is it?
Where does it go?
340
00:13:50,920 --> 00:13:52,800
- On the front,
front of the bike.
341
00:13:52,840 --> 00:13:55,040
Here we're gonna put
a handlebar and fork.
342
00:13:55,080 --> 00:13:56,960
- Oh, okay, okay.
343
00:13:57,000 --> 00:13:59,120
- Yeah, like that.
- Okay, okay, okay.
344
00:13:59,160 --> 00:14:01,120
First, the chrome spacers go
on.
345
00:14:01,160 --> 00:14:02,640
Argh!
346
00:14:02,680 --> 00:14:05,480
The front and main frame
is attached with a hinge
347
00:14:05,520 --> 00:14:08,720
to form one of the three
key folding points of the bike.
348
00:14:08,760 --> 00:14:11,040
- Like that.
349
00:14:11,120 --> 00:14:13,840
- Rafal attaches
the quick-release clamp.
350
00:14:13,920 --> 00:14:15,280
- Done?
351
00:14:15,320 --> 00:14:17,720
Next, in main frame two,
352
00:14:17,760 --> 00:14:20,200
Carl O'Brien will fit
the seat post.
353
00:14:20,240 --> 00:14:21,320
- Then place it through.
354
00:14:21,360 --> 00:14:23,240
- Which is inserted upside
down.
355
00:14:23,280 --> 00:14:25,560
- If you wanna just flip
the bike over?
356
00:14:25,600 --> 00:14:28,880
- Oh, oh.
Carl, you're a star.
357
00:14:28,920 --> 00:14:30,560
Then we need to add
358
00:14:30,600 --> 00:14:33,000
its all-important
safety features.
359
00:14:33,040 --> 00:14:34,640
But first,
Cherry's investigating
360
00:14:34,680 --> 00:14:36,120
what's being done
361
00:14:36,160 --> 00:14:40,640
to make our roads safer
for cyclists.
362
00:14:40,680 --> 00:14:42,960
[upbeat music]
363
00:14:43,000 --> 00:14:44,880
[sirens wailing]
364
00:14:44,920 --> 00:14:47,160
- As an enthusiastic
urban cyclist,
365
00:14:47,200 --> 00:14:49,120
I generally feel safe,
366
00:14:49,160 --> 00:14:52,240
but it is hard not to worry
when you see flowers laid out
367
00:14:52,280 --> 00:14:55,480
in tribute to cyclists
who've died on the roads.
368
00:14:55,520 --> 00:14:57,200
In London alone,
369
00:14:57,240 --> 00:15:01,080
there have been 66 fatalities
since 2011
370
00:15:01,160 --> 00:15:05,920
and more than half of them
were collisions with a truck.
371
00:15:05,960 --> 00:15:08,200
To find out why cyclists
and trucks
372
00:15:08,240 --> 00:15:10,640
are such a deadly
combination...
373
00:15:10,680 --> 00:15:13,120
It's a pretty big lorry.
374
00:15:13,160 --> 00:15:15,960
I'm getting behind the wheel
of an HGV.
375
00:15:16,000 --> 00:15:18,480
Whoa, that is so high!
376
00:15:18,520 --> 00:15:21,320
With instructor Doug Johnson.
377
00:15:21,360 --> 00:15:23,360
- Ready to fire it up?
- Holy moly!
378
00:15:23,440 --> 00:15:25,240
[upbeat rock music]
379
00:15:25,280 --> 00:15:27,080
- So, you bring your clutch up
gently, gently, gently.
380
00:15:27,120 --> 00:15:31,280
- Whoa!
381
00:15:31,320 --> 00:15:35,000
Oh, my God,
the weight of this thing.
382
00:15:35,040 --> 00:15:36,880
Doug's going to show me
the challenges
383
00:15:36,920 --> 00:15:38,640
of keeping cyclists safe
384
00:15:38,680 --> 00:15:41,160
from a lorry driver's
perspective.
385
00:15:41,200 --> 00:15:43,240
First, a left turn.
386
00:15:43,320 --> 00:15:44,880
- Now, looking left
and looking right,
387
00:15:44,920 --> 00:15:47,920
we're gonna treat this
like a junction, okay?
388
00:15:47,960 --> 00:15:51,760
Bring it to a nice gentle stop.
389
00:15:51,840 --> 00:15:52,720
Have a good look
in your mirrors.
390
00:15:52,760 --> 00:15:54,240
Is it clear?
391
00:15:54,280 --> 00:15:56,520
I can see the lorry,
I can see the cone.
392
00:15:56,560 --> 00:15:57,680
- If it's clear.
393
00:15:57,720 --> 00:15:59,520
- Yes, absolutely.
394
00:15:59,560 --> 00:16:00,520
- Let's just get out
and have a look
395
00:16:00,560 --> 00:16:01,640
from the outside.
396
00:16:01,680 --> 00:16:06,280
[tense pop-rock music]
397
00:16:06,320 --> 00:16:07,840
- Whoa!
398
00:16:07,880 --> 00:16:10,120
- Oh, my God!
- [group cheering]
399
00:16:10,160 --> 00:16:15,440
How is that possible
that all of you and the car...
400
00:16:15,480 --> 00:16:16,960
I can't believe it.
401
00:16:17,000 --> 00:16:20,240
Literally,
you cannot see anything.
402
00:16:20,280 --> 00:16:21,720
- Yeah, yeah, it's scary.
403
00:16:21,760 --> 00:16:24,320
This spot is so dangerous.
404
00:16:24,400 --> 00:16:27,560
Since 2015,
all lorries in London
405
00:16:27,640 --> 00:16:30,440
over 3 1/2 tons
must have special mirrors
406
00:16:30,480 --> 00:16:33,760
to improve vision
directly in front of the cab
407
00:16:33,800 --> 00:16:37,520
and both sides of the driver.
408
00:16:37,560 --> 00:16:38,840
[truck horn beeps]
409
00:16:38,880 --> 00:16:41,840
I had absolutely no idea
410
00:16:41,880 --> 00:16:44,880
that the blind spot
was such a huge area
411
00:16:44,920 --> 00:16:46,440
next to the lorry.
412
00:16:46,520 --> 00:16:49,000
It just goes to show
that when you're cycling,
413
00:16:49,080 --> 00:16:50,760
you have to be so aware.
414
00:16:53,400 --> 00:16:56,080
[upbeat music]
415
00:16:56,120 --> 00:16:59,520
- At the factory,
it's 16 hours and 15 minutes
416
00:16:59,600 --> 00:17:02,520
since I collected the parts
for my bike.
417
00:17:02,560 --> 00:17:05,000
We've bent the steel,
brazed the frame,
418
00:17:05,040 --> 00:17:08,040
and Cherry's painted it blue.
419
00:17:08,080 --> 00:17:09,560
We've put together
its front frame,
420
00:17:09,600 --> 00:17:11,760
main frame, and seat post.
421
00:17:11,800 --> 00:17:13,040
The target board shows that
422
00:17:13,080 --> 00:17:16,200
somehow,
we're still on schedule.
423
00:17:16,240 --> 00:17:17,720
Now, Gary Franklin...
424
00:17:17,800 --> 00:17:19,120
I've got another one coming in.
425
00:17:19,160 --> 00:17:21,480
Attaches the fork
for the front wheel.
426
00:17:21,520 --> 00:17:25,360
Station by station, bit by bit,
this is looking like a bike.
427
00:17:25,400 --> 00:17:26,960
- You need
to tighten the top nut,
428
00:17:27,000 --> 00:17:29,520
and then back off
the bottom nut.
429
00:17:29,560 --> 00:17:32,720
Just make sure that you can
feel the ball bearings working.
430
00:17:32,760 --> 00:17:36,480
- Then he fits the front brake,
reflector, and mudguard.
431
00:17:36,520 --> 00:17:38,080
If you don't do this right,
432
00:17:38,160 --> 00:17:39,520
does it get rejected
further down the line?
433
00:17:39,560 --> 00:17:41,480
- Yeah, it'll go down
on the computer system
434
00:17:41,520 --> 00:17:43,280
and you have a talking-to.
435
00:17:43,320 --> 00:17:44,760
- [drill whirring]
- Whoa!
436
00:17:44,800 --> 00:17:46,520
It's like being
a proper mechanic, innit?
437
00:17:46,560 --> 00:17:47,560
- Yeah.
- Cheers, mate.
438
00:17:47,600 --> 00:17:50,840
[upbeat music]
439
00:17:50,880 --> 00:17:54,280
Overseeing the entire operation
is the company CEO,
440
00:17:54,320 --> 00:17:56,960
Will Butler-Adams.
441
00:17:57,040 --> 00:17:58,200
It's not what I expected at
all.
442
00:17:58,240 --> 00:17:59,240
- Well, that's what
I was gonna ask,
443
00:17:59,320 --> 00:18:00,360
what did you expect?
444
00:18:00,400 --> 00:18:01,800
- Well, it's far more artisan.
445
00:18:01,840 --> 00:18:03,880
- I expected--
- Machines, robots.
446
00:18:03,960 --> 00:18:06,360
- 30-foot high,
yeah, automatons.
447
00:18:06,440 --> 00:18:08,520
What I didn't expect was
two rows of people.
448
00:18:08,560 --> 00:18:13,240
[upbeat music]
449
00:18:13,280 --> 00:18:15,280
Tell me about the idea
of a folding bike.
450
00:18:15,320 --> 00:18:16,640
- If you're gonna use a bike,
451
00:18:16,680 --> 00:18:17,800
you need a bike
that's convenient.
452
00:18:17,840 --> 00:18:19,400
And if you live in a city,
453
00:18:19,440 --> 00:18:21,360
dragging your big bike
is a bit of a pain.
454
00:18:21,400 --> 00:18:23,880
So, if you can have a bike,
that like a Swiss Army Knife,
455
00:18:23,920 --> 00:18:25,080
suddenly appears
when you want it,
456
00:18:25,120 --> 00:18:26,160
disappears
when you don't want it,
457
00:18:26,200 --> 00:18:28,120
it's handy.
458
00:18:28,160 --> 00:18:30,800
Whilst modern folding bikes
are made mostly for urban use,
459
00:18:30,880 --> 00:18:32,680
that hasn't always
been the case,
460
00:18:32,720 --> 00:18:37,560
as historian Ruth Goodman
is finding out.
461
00:18:37,640 --> 00:18:41,600
[dramatic music]
462
00:18:41,640 --> 00:18:43,280
- Imagine the scene.
463
00:18:43,320 --> 00:18:45,560
You are 8,000 feet
above Northern France,
464
00:18:45,600 --> 00:18:48,640
about to jump
into enemy territory.
465
00:18:48,720 --> 00:18:50,280
You've got your parachute
and your pack,
466
00:18:50,320 --> 00:18:52,360
and you've also been told
to take
467
00:18:52,400 --> 00:18:54,840
the airborne
military folding bicycle.
468
00:18:54,880 --> 00:18:57,400
[sighs]
And it's not light.
469
00:18:57,440 --> 00:18:59,160
♪
470
00:18:59,240 --> 00:19:01,120
But it was long before
the Second World War
471
00:19:01,160 --> 00:19:04,000
that folding bikes
went into military action,
472
00:19:04,040 --> 00:19:07,280
and collector Colin Kirsch
has the proof.
473
00:19:07,320 --> 00:19:12,200
So, here's the World War I
BSA folding bike.
474
00:19:12,240 --> 00:19:13,680
- And these were used in
action?
475
00:19:13,720 --> 00:19:15,560
- Yes, they made
large quantities of these.
476
00:19:15,600 --> 00:19:17,160
The problem was,
477
00:19:17,240 --> 00:19:19,880
soldiers didn't really
want to spend the time
478
00:19:19,960 --> 00:19:22,560
unfolding them
to put them on their back.
479
00:19:22,600 --> 00:19:24,120
It was one of those things
480
00:19:24,160 --> 00:19:27,640
that was not necessarily
used for its purpose.
481
00:19:27,680 --> 00:19:29,840
- Right, so it seemed like
a good idea back in the office.
482
00:19:29,880 --> 00:19:31,440
- Exactly.
- [Ruth laughs]
483
00:19:31,480 --> 00:19:33,120
♪
484
00:19:33,160 --> 00:19:36,200
Even so, by the end of the war,
in 1918,
485
00:19:36,240 --> 00:19:41,200
100,000 troops had used a bike
in active service.
486
00:19:41,240 --> 00:19:44,680
♪
487
00:19:44,720 --> 00:19:46,560
[upbeat swing-jazz music]
488
00:19:46,640 --> 00:19:48,760
They were used again
by the military from 1939,
489
00:19:48,800 --> 00:19:51,160
the start of World War II,
490
00:19:51,200 --> 00:19:53,840
first, to helps save the lives
of paratroopers,
491
00:19:53,920 --> 00:19:55,400
getting them away
from their drop zone
492
00:19:55,480 --> 00:19:56,600
as quickly as possible.
493
00:19:56,640 --> 00:19:59,080
♪
494
00:19:59,120 --> 00:20:01,000
Colin, this seems
an enormously big
495
00:20:01,040 --> 00:20:03,400
and heavy machine to be wearing
496
00:20:03,440 --> 00:20:05,640
whilst you jump out of a plane
in a parachute.
497
00:20:05,680 --> 00:20:07,920
- Oh, well,
this was probably the lightest!
498
00:20:07,960 --> 00:20:09,000
- Really?
499
00:20:09,080 --> 00:20:10,720
- Yes.
- [Ruth laughing]
500
00:20:10,800 --> 00:20:12,800
Yeah, it managed
to get the design of this one
501
00:20:12,840 --> 00:20:15,120
under 20 pounds in weight.
502
00:20:15,160 --> 00:20:17,400
- It would give you mobility
once you got on the ground,
503
00:20:17,440 --> 00:20:19,600
if you were off trying
to find specific targets.
504
00:20:19,640 --> 00:20:22,720
- As long as you
weren't under fire.
505
00:20:22,760 --> 00:20:24,400
- So, did they see much action?
506
00:20:24,440 --> 00:20:27,960
- Yes, there were two
major campaigns they were used.
507
00:20:28,000 --> 00:20:32,040
They were used on D-Day
in the landing craft
508
00:20:32,080 --> 00:20:34,600
and they were used
at Market Garden,
509
00:20:34,680 --> 00:20:36,640
[majestic music]
510
00:20:36,720 --> 00:20:38,640
- How does it go together then?
It sort of--
511
00:20:38,720 --> 00:20:42,120
- Right. Let's...
512
00:20:42,160 --> 00:20:43,840
You wouldn't want to do this
under fire.
513
00:20:43,880 --> 00:20:44,920
- You wouldn't, would you?
514
00:20:44,960 --> 00:20:46,920
♪
515
00:20:46,960 --> 00:20:48,280
- Fabulous design.
516
00:20:48,360 --> 00:20:50,240
♪ ♪
517
00:20:50,320 --> 00:20:55,200
Ready to jump on and ride away.
518
00:20:55,240 --> 00:20:59,760
- 70,000 of the so-called
parabikes were manufactured,
519
00:20:59,840 --> 00:21:03,000
but British paratroopers
weren't keen to ride them,
520
00:21:03,040 --> 00:21:06,040
and at the end of the war,
thousands were stockpiled
521
00:21:06,080 --> 00:21:09,160
and then sold off
as army surplus.
522
00:21:09,200 --> 00:21:11,800
[groovy upbeat music]
523
00:21:11,840 --> 00:21:13,600
It wasn't until the 1960s
524
00:21:13,640 --> 00:21:17,560
that folding and packaway bikes
came back into favor.
525
00:21:17,600 --> 00:21:19,120
Now they were fashionable and,
526
00:21:19,160 --> 00:21:22,400
thanks to the much smaller
16-inch wheels,
527
00:21:22,440 --> 00:21:24,600
also practical.
528
00:21:24,640 --> 00:21:27,600
The next big breakthrough
was in 1971,
529
00:21:27,640 --> 00:21:29,240
when Harry Bickerton
530
00:21:29,280 --> 00:21:31,920
came up with a new, light,
and compact design,
531
00:21:31,960 --> 00:21:35,600
which set the standard
for folding bikes.
532
00:21:35,680 --> 00:21:37,560
Four years later, Andrew
Ritchie
533
00:21:37,600 --> 00:21:40,320
came up with his own invention,
the Brompton.
534
00:21:40,360 --> 00:21:45,560
♪
535
00:21:45,600 --> 00:21:47,120
[metal clanking]
536
00:21:47,200 --> 00:21:49,880
- Back at the factory,
Will's filling me in
537
00:21:49,920 --> 00:21:54,280
on how that invention was
turned into a commercial
product.
538
00:21:54,320 --> 00:21:56,480
Andrew Ritchie came up
with the idea in his flat,
539
00:21:56,560 --> 00:21:58,320
overlooking
the Brompton Oratory,
540
00:21:58,360 --> 00:21:59,720
came up with the name,
541
00:21:59,800 --> 00:22:01,560
and decided,
"Perfect, I'm a genius,
542
00:22:01,600 --> 00:22:02,840
"everyone's gonna
want my design."
543
00:22:02,880 --> 00:22:04,440
Gave it to Raleigh,
544
00:22:04,480 --> 00:22:06,080
they looked at it
and decided it was bonkers,
545
00:22:06,120 --> 00:22:07,600
didn't want to do it.
546
00:22:07,680 --> 00:22:08,800
And after everyone else
turned it down,
547
00:22:08,840 --> 00:22:09,760
he decided to do it himself.
548
00:22:09,800 --> 00:22:11,280
[upbeat electronic music]
549
00:22:11,320 --> 00:22:12,640
- In the early '80s,
550
00:22:12,720 --> 00:22:15,600
Andrew began making bikes
on a small scale
551
00:22:15,640 --> 00:22:17,280
from his home in west London.
552
00:22:17,320 --> 00:22:18,960
But making a profit was tough
553
00:22:19,040 --> 00:22:20,920
and when the banks
refused him a loan,
554
00:22:20,960 --> 00:22:24,440
it was almost the end
of the road.
555
00:22:24,480 --> 00:22:26,480
- One of his customers,
who was so frustrated
556
00:22:26,560 --> 00:22:28,280
that he couldn't buy
any more of the bikes,
557
00:22:28,320 --> 00:22:31,160
that came in with the 40 grand
he needed in 1988,
558
00:22:31,200 --> 00:22:34,680
and after 13 years of struggle,
he got started.
559
00:22:34,720 --> 00:22:36,960
- He got his bike fan-funded.
560
00:22:37,000 --> 00:22:39,320
- Early fan-funding.
- He did, didn't he?
561
00:22:39,400 --> 00:22:42,160
[upbeat music]
562
00:22:42,200 --> 00:22:46,240
This factory produces
46,000 bikes a year,
563
00:22:46,280 --> 00:22:47,840
and to help them keep on
target,
564
00:22:47,920 --> 00:22:50,840
I need to get mine
back on the assembly line.
565
00:22:50,880 --> 00:22:52,800
It's just over 16 hours
566
00:22:52,840 --> 00:22:55,240
and 18 minutes since I started
567
00:22:55,280 --> 00:22:57,480
and now Hubert Stritzi
attaches the rear section
568
00:22:57,560 --> 00:22:58,840
to the main frame
569
00:22:58,880 --> 00:23:02,280
for the second
key folding point.
570
00:23:02,320 --> 00:23:04,200
- Put rear frame.
571
00:23:04,240 --> 00:23:07,000
- [drill whirring]
- Ah. I can do this.
572
00:23:07,040 --> 00:23:08,160
[drill whirring]
573
00:23:08,200 --> 00:23:10,600
Okay, and now use this spanner.
574
00:23:10,680 --> 00:23:12,040
Look in your ear.
575
00:23:12,080 --> 00:23:13,320
- It's okay?
- Clear?
576
00:23:13,360 --> 00:23:16,080
[both laughing]
577
00:23:16,120 --> 00:23:18,760
- Next, we're going to give
my bike its mudguard,
578
00:23:18,800 --> 00:23:20,600
racks, and rear brakes.
579
00:23:20,640 --> 00:23:22,520
♪
580
00:23:22,560 --> 00:23:25,600
Helping me is Michelle
Makelogi.
581
00:23:25,640 --> 00:23:27,080
- I'm gonna show you one side
582
00:23:27,120 --> 00:23:28,800
and then you can tighten
the other one.
583
00:23:28,840 --> 00:23:30,960
- That's all right?
- All right.
584
00:23:31,040 --> 00:23:33,880
- So, you just go like this.
- [drill whirring]
585
00:23:33,920 --> 00:23:35,680
[drill whirring]
586
00:23:35,720 --> 00:23:36,720
- That's it.
- That's it, right?
587
00:23:36,760 --> 00:23:39,360
[upbeat pop-rock music]
588
00:23:39,400 --> 00:23:43,440
Next stop for my bike
is fork two, and Noel Peters.
589
00:23:43,480 --> 00:23:44,880
- Noel.
590
00:23:44,920 --> 00:23:46,440
- All the experienced workers
like Noel
591
00:23:46,480 --> 00:23:50,600
swap over their stations
from day to day.
592
00:23:50,680 --> 00:23:52,800
Noel, you seem very confident.
Have you been here a while?
593
00:23:52,840 --> 00:23:57,120
- Yeah, since May 2001.
- Wow.
594
00:23:57,200 --> 00:23:59,800
On his station today,
Noel puts on the mud flaps
595
00:23:59,840 --> 00:24:01,840
and attaches
the derailleur cables
596
00:24:01,880 --> 00:24:04,680
that will make
the bike's gears change.
597
00:24:04,720 --> 00:24:06,920
You're part-man,
part-bicycle now, aren't you?
598
00:24:06,960 --> 00:24:08,760
- [laughs]
I think I'm robot now.
599
00:24:08,800 --> 00:24:09,840
Complete robot!
600
00:24:09,920 --> 00:24:12,000
[both laughing]
601
00:24:12,040 --> 00:24:16,000
They use more than half a mile
of cable a day.
602
00:24:16,040 --> 00:24:17,760
- Can I do this?
- I wasn't leaving you out.
603
00:24:17,800 --> 00:24:18,640
- Get off, get off. Get off.
- All right.
604
00:24:18,720 --> 00:24:20,760
[laughs]
605
00:24:20,800 --> 00:24:22,600
- [drill whirring]
- [bolt clicks]
606
00:24:22,640 --> 00:24:24,200
When you hear that click,
that's done, yeah?
607
00:24:24,240 --> 00:24:25,280
- That's it, yeah.
That's what we've done.
608
00:24:25,320 --> 00:24:26,560
- Cable in, mudguard in.
609
00:24:26,600 --> 00:24:28,080
- Yes, that's the one.
610
00:24:28,120 --> 00:24:29,160
- What do you think
when you see someone
611
00:24:29,200 --> 00:24:30,600
on the train with one of these?
612
00:24:30,640 --> 00:24:32,840
- I say, "Wow,
I had a hand in that.
613
00:24:32,880 --> 00:24:34,960
"And a few others." That's me.
614
00:24:35,000 --> 00:24:37,960
Hand-made by me.
I feel proud.
615
00:24:38,000 --> 00:24:41,240
♪
616
00:24:43,880 --> 00:24:47,160
[upbeat music]
617
00:24:47,200 --> 00:24:48,680
- Back on the production line,
618
00:24:48,720 --> 00:24:51,320
and my bike
is just over 16 1/2 hours
619
00:24:51,400 --> 00:24:54,160
into its journey
from parts to packaging.
620
00:24:54,200 --> 00:24:57,680
It's now got forks,
mudguards, and brakes,
621
00:24:57,720 --> 00:24:58,880
but it's still missing
622
00:24:58,960 --> 00:25:01,560
two of the most crucial
components.
623
00:25:01,600 --> 00:25:02,920
Do you make the wheels?
624
00:25:02,960 --> 00:25:04,400
- I do.
- I need two wheels.
625
00:25:04,440 --> 00:25:05,520
I need a back wheel
and a front wheel.
626
00:25:05,600 --> 00:25:07,640
- Yeah, sure.
627
00:25:07,680 --> 00:25:10,720
- Behind the main assembly
line, Rudi Yousef fits the
inner tubes
628
00:25:10,760 --> 00:25:13,000
and tires onto the wheel rims.
629
00:25:13,080 --> 00:25:14,920
And, like the other
time-critical stations,
630
00:25:14,960 --> 00:25:17,240
he has just 3 1/2 minutes
631
00:25:17,280 --> 00:25:20,720
or he'll hold up
the whole production.
632
00:25:20,760 --> 00:25:22,520
How many wheels do you do a
day?
633
00:25:22,560 --> 00:25:24,600
- Over 300 wheels a day, yeah.
634
00:25:24,680 --> 00:25:26,840
- These wheel rims
are designed here
635
00:25:26,880 --> 00:25:29,120
but made off-site.
636
00:25:29,160 --> 00:25:31,400
They only have
a 16-inch diameter,
637
00:25:31,480 --> 00:25:35,200
10 inches smaller
than a standard bike wheel.
638
00:25:35,280 --> 00:25:37,280
Their reduced size
makes them stronger
639
00:25:37,320 --> 00:25:40,120
and helps
the bike accelerate faster.
640
00:25:40,160 --> 00:25:41,720
Rudi, stand aside.
641
00:25:41,800 --> 00:25:43,800
Let me show you how you do
wheels properly, son.
642
00:25:43,840 --> 00:25:45,200
- Yeah, you just lock it in.
643
00:25:45,240 --> 00:25:47,960
First of all, I need to apply
a protective tape
644
00:25:48,040 --> 00:25:51,760
and get the inner tube
and tire to fit snugly on top.
645
00:25:51,840 --> 00:25:54,720
This is very, very fiddly.
646
00:25:54,760 --> 00:25:57,000
To help protect these tires
from punctures,
647
00:25:57,040 --> 00:25:59,040
they're reinforced with Kevlar,
648
00:25:59,120 --> 00:26:02,560
an ultra-strong material
used in bulletproof vests.
649
00:26:02,600 --> 00:26:04,120
Can I stand back
and just let you do one?
650
00:26:04,160 --> 00:26:05,600
- No, no, no.
651
00:26:05,640 --> 00:26:07,280
- 'Cause I need two wheels
for my bike.
652
00:26:07,320 --> 00:26:10,800
Now, with help from Rudi,
I can inflate the tire.
653
00:26:10,840 --> 00:26:12,320
It always puts the right
amount of air in, does it?
654
00:26:12,360 --> 00:26:15,960
- Oh, 'cause it's automatically
set at 100 psi.
655
00:26:16,000 --> 00:26:18,520
- So, other tires,
on other bikes,
656
00:26:18,600 --> 00:26:20,360
they normally have a lower psi.
657
00:26:20,400 --> 00:26:21,960
You have 100, which is higher,
658
00:26:22,000 --> 00:26:22,800
because you have
a smaller wheel.
659
00:26:22,840 --> 00:26:24,160
- Yeah.
660
00:26:24,200 --> 00:26:25,240
- And is that because,
I suppose,
661
00:26:25,280 --> 00:26:26,760
the wheel is doing more work?
662
00:26:26,800 --> 00:26:28,160
- Yeah, yeah, yeah.
- Yeah, yeah, yeah.
663
00:26:28,200 --> 00:26:30,160
- It's going round more often.
- Yeah.
664
00:26:30,200 --> 00:26:35,280
The expert in wheel engineering
is design manager Paul
Williams.
665
00:26:35,320 --> 00:26:37,240
Is the wheel the trickiest bit
on a folding bike?
666
00:26:37,280 --> 00:26:39,520
- It's one of the parts
that needs to be best built,
667
00:26:39,560 --> 00:26:40,960
lasts longest,
668
00:26:41,000 --> 00:26:42,160
because it's gonna see
a lot of wear,
669
00:26:42,200 --> 00:26:45,280
constant braking,
constant acceleration.
670
00:26:45,320 --> 00:26:47,040
- Regular cycling commuters
671
00:26:47,080 --> 00:26:50,000
can travel more than 1,300
miles in a year,
672
00:26:50,080 --> 00:26:52,560
so it's essential
their bikes are robust
673
00:26:52,600 --> 00:26:54,280
and lightweight.
674
00:26:54,320 --> 00:26:56,920
- That might be down to this
nut being two grams lighter.
675
00:26:56,960 --> 00:26:58,360
- How many bits on the bike?
676
00:26:58,400 --> 00:27:00,200
- 1,200-odd,
677
00:27:00,240 --> 00:27:01,800
and if we can take a little bit
out of each of those,
678
00:27:01,840 --> 00:27:04,080
then we will add up to
something quite considerable.
679
00:27:04,120 --> 00:27:06,560
- It's a constant challenge
for the design team
680
00:27:06,600 --> 00:27:10,880
to balance the bike's weight,
durability, and cost.
681
00:27:10,920 --> 00:27:12,640
- If you make something
stronger,
682
00:27:12,680 --> 00:27:13,960
it's often got more material
in, so it's not as light.
683
00:27:14,040 --> 00:27:15,400
If you make it lighter,
684
00:27:15,440 --> 00:27:16,840
it normally means
more exotic material.
685
00:27:16,880 --> 00:27:18,840
It's hard to do that cheaply.
686
00:27:18,880 --> 00:27:20,360
- The company invests heavily
687
00:27:20,400 --> 00:27:22,520
in researching
the latest technologies
688
00:27:22,600 --> 00:27:27,120
and they know a comfortable
ride is also important.
689
00:27:27,160 --> 00:27:29,280
Nowadays,
we take it for granted,
690
00:27:29,320 --> 00:27:31,960
but early bikes weren't
designed with luxury in mind,
691
00:27:32,000 --> 00:27:35,640
as Ruth Goodman
has been finding out.
692
00:27:35,720 --> 00:27:38,320
[upbeat funky music]
693
00:27:38,360 --> 00:27:40,000
- In the 19th century,
694
00:27:40,040 --> 00:27:43,880
cycling was almost exclusively
a male pursuit.
695
00:27:43,960 --> 00:27:46,480
In 1817,
the first popular two-wheeler
696
00:27:46,520 --> 00:27:47,920
was thought
to have been invented
697
00:27:48,000 --> 00:27:49,200
in Germany.
698
00:27:49,280 --> 00:27:51,440
It was named the dandy horse
699
00:27:51,520 --> 00:27:55,160
because it was fashionable
with wealthy young men.
700
00:27:55,240 --> 00:27:57,960
More than 40 years later,
the boneshaker,
701
00:27:58,000 --> 00:28:00,840
with its iron-shod rims,
wooden wheels,
702
00:28:00,880 --> 00:28:06,000
and a very solid frame,
also had pedals.
703
00:28:06,040 --> 00:28:07,560
In the 1870s,
704
00:28:07,600 --> 00:28:12,240
the penny-farthing
was still for men only.
705
00:28:12,280 --> 00:28:15,680
Bike historian Doug Pinkerton
shows me why.
706
00:28:15,760 --> 00:28:18,280
That is what we call
forward dismount.
707
00:28:18,320 --> 00:28:21,280
It looks really difficult
to ride.
708
00:28:21,320 --> 00:28:24,640
How on earth did women manage
with the big skirts?
709
00:28:24,680 --> 00:28:26,200
Ladies, at the time,
710
00:28:26,240 --> 00:28:27,920
they weren't riding
these machines.
711
00:28:27,960 --> 00:28:29,440
It was the none-done thing
to do.
712
00:28:29,480 --> 00:28:31,560
In public places,
you didn't even show
713
00:28:31,640 --> 00:28:32,960
so much as an ankle,
714
00:28:33,000 --> 00:28:35,200
so riding a bicycle
of this design
715
00:28:35,240 --> 00:28:36,240
was totally out of the
question.
716
00:28:36,280 --> 00:28:37,720
Totally impossible.
717
00:28:37,760 --> 00:28:39,560
- So, ladies actually
rode tricycles.
718
00:28:39,640 --> 00:28:43,440
[gentle upbeat music]
719
00:28:43,480 --> 00:28:46,080
- This ladies tricycle,
from 1886,
720
00:28:46,120 --> 00:28:49,040
has an ingenious
lifting handlebar
721
00:28:49,080 --> 00:28:52,000
to help ladies
mount in bulky dresses.
722
00:28:52,040 --> 00:28:54,200
Slide in,
put the handlebars back.
723
00:28:54,280 --> 00:28:56,000
- Yep.
724
00:28:56,040 --> 00:28:58,400
- Marvelous.
Leg over in a decorous manner.
725
00:28:58,440 --> 00:29:00,720
[upbeat music]
726
00:29:00,760 --> 00:29:03,560
♪
727
00:29:03,600 --> 00:29:05,920
Oh, my goodness!
728
00:29:05,960 --> 00:29:08,000
This is not an
easy bike to ride.
729
00:29:08,040 --> 00:29:11,320
- No, very cumbersome,
very slow.
730
00:29:11,400 --> 00:29:15,240
- Fears that rigorous movement
could ruin the feminine organs
731
00:29:15,280 --> 00:29:17,360
of matrimonial necessity
732
00:29:17,400 --> 00:29:20,880
meant Victorian women
were discouraged from cycling.
733
00:29:20,920 --> 00:29:22,600
It's sort of annoying,
734
00:29:22,640 --> 00:29:24,320
in that the men have
all this freedom on the bike
735
00:29:24,360 --> 00:29:26,520
and you, as a woman,
are gonna be trailing behind
736
00:29:26,560 --> 00:29:29,200
because you've got
to do it decorously.
737
00:29:29,280 --> 00:29:32,240
- Yes, you really were
almost a second-class citizen.
738
00:29:32,320 --> 00:29:36,360
- You sacrifice so much
with this upright posture.
739
00:29:36,400 --> 00:29:38,160
- Very much so.
740
00:29:38,200 --> 00:29:40,160
- But things improved
for women cyclists
741
00:29:40,200 --> 00:29:41,720
in the late 1880s,
742
00:29:41,760 --> 00:29:44,240
with the invention
of the safety bike,
743
00:29:44,280 --> 00:29:47,680
the direct ancestor
of today's diamond-frame bike.
744
00:29:47,720 --> 00:29:51,080
Equal-sized wheels and lighter,
more responsive steering
745
00:29:51,120 --> 00:29:54,600
made this a far easier ride.
746
00:29:54,680 --> 00:29:56,320
- This is the sort of period
747
00:29:56,360 --> 00:29:58,480
when ladies were starting
to use cycles.
748
00:29:58,520 --> 00:30:00,080
- So, for the first time,
749
00:30:00,120 --> 00:30:01,760
men and women are on the same
style of bicycle.
750
00:30:01,800 --> 00:30:03,200
- Style of machine.
- Exactly, yes.
751
00:30:03,280 --> 00:30:05,120
- So, this, really,
would give you,
752
00:30:05,160 --> 00:30:07,640
particularly as a woman,
a lot more freedom
753
00:30:07,680 --> 00:30:09,320
than the earlier styles
would have done.
754
00:30:09,360 --> 00:30:13,320
- The new improved
safety bicycle era, after 1885,
755
00:30:13,360 --> 00:30:15,880
because of its design,
certainly liberated women
756
00:30:15,920 --> 00:30:17,800
to come and enjoy
the sport of cycling.
757
00:30:17,880 --> 00:30:20,120
[upbeat music]
758
00:30:20,160 --> 00:30:22,680
- And one group
who embraced this change
759
00:30:22,720 --> 00:30:26,200
were the suffragettes.
760
00:30:26,240 --> 00:30:28,520
According to research
fellow Sheila Hanlon,
761
00:30:28,600 --> 00:30:33,960
bicycles were vital to women
gaining freedom and the vote.
762
00:30:34,000 --> 00:30:36,520
So, why are we here
in Hyde Park?
763
00:30:36,560 --> 00:30:38,280
- Hyde Park was the site
764
00:30:38,320 --> 00:30:41,880
of a really important
suffragettes' rally in 1913.
765
00:30:41,920 --> 00:30:43,600
It wasn't just a rally,
766
00:30:43,640 --> 00:30:45,600
it was actually a pilgrimage
to get to the rally.
767
00:30:45,640 --> 00:30:47,640
- "Land's End to London."
768
00:30:47,680 --> 00:30:49,640
If you look really closely
in the front,
769
00:30:49,680 --> 00:30:52,960
you'll see
there's a line of cyclists.
770
00:30:53,040 --> 00:30:54,720
They're upfront
in the photograph
771
00:30:54,800 --> 00:30:56,160
and that really reflects
the central role
772
00:30:56,200 --> 00:30:59,880
that they played
in organizing the pilgrimage.
773
00:30:59,920 --> 00:31:01,760
This postcard
is a different route
774
00:31:01,800 --> 00:31:05,160
and, again, the row of cyclists
are right up at the front.
775
00:31:05,240 --> 00:31:06,640
- Yes, they are.
Whole load of them--
776
00:31:06,720 --> 00:31:07,560
- There's quite a few of them.
- Yeah.
777
00:31:07,600 --> 00:31:09,320
And what they're doing
778
00:31:09,360 --> 00:31:11,360
is they're taking pamphlets
and handing them out,
779
00:31:11,400 --> 00:31:14,040
they're holding meetings
in village greens,
780
00:31:14,080 --> 00:31:15,160
and they're really using
their bicycles
781
00:31:15,200 --> 00:31:16,560
as a way to get out there
782
00:31:16,600 --> 00:31:18,680
and tell more people
about the need
783
00:31:18,720 --> 00:31:20,480
for the vote for women.
784
00:31:20,560 --> 00:31:22,600
And then they all converge
at the end,
785
00:31:22,640 --> 00:31:25,960
in London, in the park
where we are today.
786
00:31:26,000 --> 00:31:28,040
- So, how many people
ended up here?
787
00:31:28,120 --> 00:31:30,400
- We think it was
about 50,000 people,
788
00:31:30,440 --> 00:31:33,520
which is a formidable crowd.
789
00:31:33,560 --> 00:31:35,120
- The bicycle, itself,
790
00:31:35,160 --> 00:31:37,520
was part of the sort
of tools of the trade
791
00:31:37,560 --> 00:31:40,160
for independent-minded women
to get out there
792
00:31:40,200 --> 00:31:42,760
and be part
of the political process.
793
00:31:42,800 --> 00:31:44,920
- The bicycle
really was a small cog
794
00:31:45,000 --> 00:31:47,240
in a very big wheel for change
795
00:31:47,280 --> 00:31:51,040
and I think it was essential
to how women achieved the vote.
796
00:31:51,080 --> 00:31:54,040
[upbeat music]
797
00:31:54,080 --> 00:31:59,280
♪
798
00:32:05,320 --> 00:32:07,240
[upbeat groovy music]
799
00:32:07,280 --> 00:32:08,640
- At the bike factory...
800
00:32:08,680 --> 00:32:11,040
Wheels!
Front wheel.
801
00:32:11,080 --> 00:32:12,480
- Yes.
- Rear wheel.
802
00:32:12,520 --> 00:32:14,600
It's almost 16 1/2 hours
803
00:32:14,640 --> 00:32:17,440
since I collected
the raw steel parts.
804
00:32:17,520 --> 00:32:19,600
I'm guessing
it goes on that way.
805
00:32:19,640 --> 00:32:21,440
And, as Amelia Maticevska and I
806
00:32:21,520 --> 00:32:23,360
put on the wheels
and handlebars,
807
00:32:23,400 --> 00:32:27,240
it's really starting to look
like the finished product.
808
00:32:27,320 --> 00:32:28,320
Hey!
809
00:32:28,360 --> 00:32:29,800
[upbeat music]
810
00:32:29,880 --> 00:32:32,160
But it's still not fit to ride.
811
00:32:32,200 --> 00:32:35,120
I need to tighten
and align the brake pads.
812
00:32:35,160 --> 00:32:37,960
You gotta strong arms!
With Omar Ahmed Omar.
813
00:32:38,000 --> 00:32:39,480
You happy?
814
00:32:39,520 --> 00:32:41,080
- Not really.
- What's wrong?
815
00:32:41,160 --> 00:32:42,800
- Because it's not straight.
816
00:32:42,840 --> 00:32:45,200
- All right, you do it.
Sorry, Omar, you do it.
817
00:32:45,240 --> 00:32:48,200
I'm not very good at brakes.
818
00:32:48,240 --> 00:32:50,240
Now I'm ready to fit
the mechanism
819
00:32:50,280 --> 00:32:54,760
that will make my bike move:
the pedals, crank, and chain.
820
00:32:54,800 --> 00:32:57,920
Ah! That's tight, mate.
821
00:32:57,960 --> 00:32:59,520
For crying out loud!
822
00:32:59,560 --> 00:33:01,400
You'll have shoulders
like Schwarzenegger!
823
00:33:01,440 --> 00:33:04,480
♪
824
00:33:04,520 --> 00:33:05,800
It's incredible to think
825
00:33:05,880 --> 00:33:09,240
these guys build 22 bikes
an hour
826
00:33:09,280 --> 00:33:11,720
but, according
to the target board,
827
00:33:11,760 --> 00:33:13,520
we've slipped behind,
828
00:33:13,560 --> 00:33:16,120
and I'm pretty sure
I'm the one causing the holdup.
829
00:33:16,160 --> 00:33:17,880
I'm really sorry!
830
00:33:17,960 --> 00:33:19,320
I'm sorry,
I was chatting, I'm sorry.
831
00:33:19,360 --> 00:33:20,800
- I didn't wanna say anything,
but--
832
00:33:20,840 --> 00:33:22,040
- That's what happens.
Everyone stops.
833
00:33:22,080 --> 00:33:23,120
- Do you think
we move it on now?
834
00:33:23,160 --> 00:33:24,440
- Let's go, let's go!
835
00:33:24,520 --> 00:33:25,640
I'm getting it.
I'm getting it.
836
00:33:25,680 --> 00:33:27,280
- Into the next station.
837
00:33:27,320 --> 00:33:29,880
- I've got you,
I've got you, I've got you.
838
00:33:29,920 --> 00:33:32,560
My next station is rear brake.
839
00:33:32,600 --> 00:33:34,480
First, we set up
the brake cables
840
00:33:34,560 --> 00:33:37,040
and try and get my bike
back on track.
841
00:33:37,120 --> 00:33:38,200
What are you doing?
842
00:33:38,240 --> 00:33:39,960
Come on, man, we've gotta move!
843
00:33:40,000 --> 00:33:42,080
Let's go, let's go!
We've got bikes to make!
844
00:33:42,160 --> 00:33:43,920
♪ ♪
845
00:33:43,960 --> 00:33:45,520
- What do you think these are?
846
00:33:45,560 --> 00:33:47,040
We've got another set of wheels
going here.
847
00:33:47,120 --> 00:33:48,560
I think that's because
the bike folds up.
848
00:33:48,600 --> 00:33:50,120
- Yeah.
849
00:33:50,200 --> 00:33:52,240
- And it's got to roll,
rather than clank.
850
00:33:52,280 --> 00:33:53,720
Unless you're gonna ride it
upside down,
851
00:33:53,760 --> 00:33:55,840
that's to fold it, right?
852
00:33:55,880 --> 00:33:57,480
When the bike's packed down,
853
00:33:57,520 --> 00:34:01,800
these extra little wheels
let the cyclist pull it along.
854
00:34:01,840 --> 00:34:03,720
Seeing how it folds up
makes me realize
855
00:34:03,760 --> 00:34:08,880
why pressing the steel
into a curve was so important.
856
00:34:08,920 --> 00:34:10,960
The reason that's curved
is so a wheel fits under it
857
00:34:11,000 --> 00:34:12,320
when it's folded.
858
00:34:12,400 --> 00:34:13,880
- One of. Yes.
- That's the reason.
859
00:34:13,920 --> 00:34:15,440
But that gives it
a unique look as well.
860
00:34:15,480 --> 00:34:16,760
I'm so getting the hang
of this bike lark!
861
00:34:16,800 --> 00:34:20,120
[upbeat dance music]
862
00:34:20,200 --> 00:34:21,920
There's lots of engineering
863
00:34:21,960 --> 00:34:23,840
that goes into making
a modern bicycle,
864
00:34:23,880 --> 00:34:27,880
but that, to me, is nothing
if it's not comfortable.
865
00:34:27,960 --> 00:34:29,840
Now, when you order a bike
from this factory,
866
00:34:29,880 --> 00:34:31,560
you get a standard saddle
867
00:34:31,600 --> 00:34:34,560
but if you really want luxury
for your bottom,
868
00:34:34,600 --> 00:34:35,720
you can get a hand-made one.
869
00:34:35,760 --> 00:34:38,960
[upbeat pop-rock music]
870
00:34:39,000 --> 00:34:40,840
Brooks, based in Birmingham,
871
00:34:40,880 --> 00:34:44,560
has been making leather saddles
for almost 150 years.
872
00:34:44,640 --> 00:34:47,400
♪ ♪
873
00:34:47,440 --> 00:34:51,440
The company was started in 1866
by John Boultbee Brooks,
874
00:34:51,480 --> 00:34:55,200
who began with horse harnesses
and saddles.
875
00:34:55,240 --> 00:34:57,040
But when his own horse died,
876
00:34:57,080 --> 00:35:00,360
he decided to switch
to making bicycle saddles.
877
00:35:00,440 --> 00:35:02,360
I've come to make a saddle.
878
00:35:02,400 --> 00:35:03,880
Is this where I start?
- Yeah.
879
00:35:03,920 --> 00:35:06,360
- Master cutter,
Ricky Ravenhill,
880
00:35:06,400 --> 00:35:08,240
needs to get
as many as 11 of them
881
00:35:08,320 --> 00:35:10,360
out of each cowhide.
882
00:35:10,400 --> 00:35:11,720
You wanna try and cut one?
883
00:35:11,760 --> 00:35:12,800
- Crikey, really?
884
00:35:12,880 --> 00:35:15,040
- You get the knife
885
00:35:15,120 --> 00:35:17,240
and as close to the edge
as possible.
886
00:35:17,280 --> 00:35:20,040
And then swing that round
so it's in the middle
887
00:35:20,120 --> 00:35:22,920
and then press those down
and as soon as you feel
888
00:35:22,960 --> 00:35:25,720
it's hit the pressure,
release them.
889
00:35:25,760 --> 00:35:27,040
[machine clunks]
890
00:35:27,080 --> 00:35:29,320
That should be perfect.
891
00:35:29,360 --> 00:35:31,600
- Almost all their leather
comes from the UK and Ireland,
892
00:35:31,640 --> 00:35:32,880
where the cold weather
893
00:35:32,920 --> 00:35:35,120
means the cows
have thicker skins,
894
00:35:35,160 --> 00:35:38,080
up to nearly six millimeters,
895
00:35:38,120 --> 00:35:40,520
which can support
the weight of a body.
896
00:35:40,560 --> 00:35:43,160
- Start of my saddle, right?
- Voila, yeah.
897
00:35:43,200 --> 00:35:46,000
Next, Gurdip Sangha
softens the leather in water
898
00:35:46,080 --> 00:35:48,160
for 20 to 40 minutes.
899
00:35:48,200 --> 00:35:49,480
Bit like fishing, mate, innit?
900
00:35:49,520 --> 00:35:51,920
- It is, definitely.
901
00:35:51,960 --> 00:35:54,120
That's it.
902
00:35:54,160 --> 00:35:57,280
- After it's naturally
air-dried for up to 12 hours,
903
00:35:57,320 --> 00:36:00,560
it's molded
to create the saddle shape.
904
00:36:00,640 --> 00:36:02,600
- Mate, we're virtually there.
- Yeah.
905
00:36:02,640 --> 00:36:04,600
- We're virtually there.
We've got a saddle.
906
00:36:04,640 --> 00:36:07,240
♪
907
00:36:07,280 --> 00:36:11,920
I let someone experienced
slice off the excess leather.
908
00:36:11,960 --> 00:36:15,200
And then my saddle is ready
for curing in the oven.
909
00:36:15,240 --> 00:36:17,400
If I don't come out
in five minutes,
910
00:36:17,440 --> 00:36:19,880
call my mum!
911
00:36:19,920 --> 00:36:22,440
Nearly three hours later,
and my leather seat
912
00:36:22,480 --> 00:36:24,840
gets its rough edges
sanded away.
913
00:36:24,920 --> 00:36:28,200
♪ ♪
914
00:36:28,240 --> 00:36:30,200
The seat will be fixed
onto a frame
915
00:36:30,240 --> 00:36:33,320
made from high-tensile
steel rails,
916
00:36:33,400 --> 00:36:37,920
with a backplate pressed
from more high-quality steel.
917
00:36:38,000 --> 00:36:39,760
By the time the frame is ready,
918
00:36:39,800 --> 00:36:42,800
it's been double-coated
in nickel and copper,
919
00:36:42,840 --> 00:36:45,400
it's been lacquered and baked,
920
00:36:45,440 --> 00:36:48,400
but it's not a saddle
until it's been put together.
921
00:36:48,440 --> 00:36:50,680
And that's the job
of Eric Murray.
922
00:36:50,720 --> 00:36:51,840
- How do you do, sir?
923
00:36:51,880 --> 00:36:53,880
I've gotta attach this to this.
924
00:36:53,920 --> 00:36:55,360
Can you show me how to do this?
925
00:36:55,400 --> 00:36:56,960
- I will, sir.
926
00:36:57,000 --> 00:36:59,240
- First up, Eric makes holes
in the leather.
927
00:36:59,280 --> 00:37:00,920
Are you pressing a button
to make the holes?
928
00:37:00,960 --> 00:37:02,600
- Can I do it?
- You can now, sir.
929
00:37:02,640 --> 00:37:04,400
- Stand back, son, stand back.
930
00:37:07,000 --> 00:37:08,840
- Brilliant,
absolutely brilliant.
931
00:37:08,880 --> 00:37:11,280
- What is it about saddles?
932
00:37:11,320 --> 00:37:14,360
- It's your hands, innit?
You're working with your hands.
933
00:37:14,400 --> 00:37:15,720
- You can't imagine yourself
behind a desk with a tie on?
934
00:37:15,760 --> 00:37:17,440
- Oh, no, no, no. No way!
935
00:37:17,480 --> 00:37:19,400
I'm sorry, cock, no.
936
00:37:19,440 --> 00:37:21,760
I couldn't do that,
cocker, no way!
937
00:37:21,840 --> 00:37:23,680
Them people deserve medals
938
00:37:23,720 --> 00:37:27,240
because I couldn't sit there
fiddling a computer.
939
00:37:27,320 --> 00:37:31,240
- Next, Eric has to chamfer
or trim off the leather
940
00:37:31,280 --> 00:37:33,640
to create a smooth beveled
edge.
941
00:37:33,680 --> 00:37:34,920
Eric the chamferer.
942
00:37:34,960 --> 00:37:36,640
- Eric the chamferer and all.
943
00:37:36,720 --> 00:37:38,560
- That's highly skilled.
944
00:37:38,600 --> 00:37:40,080
If you get that wrong,
at that stage,
945
00:37:40,120 --> 00:37:41,720
you've ruined a whole saddle.
946
00:37:41,760 --> 00:37:43,480
How many do you spoil?
- I don't.
947
00:37:43,520 --> 00:37:45,880
You've just gotta be
just that little bit careful.
948
00:37:45,960 --> 00:37:47,520
- And that gives
a smoother finish.
949
00:37:47,560 --> 00:37:48,440
- That's a bet.
950
00:37:48,520 --> 00:37:49,600
- Saves chafing.
951
00:37:49,640 --> 00:37:51,440
- That's it, exactly.
952
00:37:51,520 --> 00:37:55,320
- Next, he puts a noseplate
in the front of my saddle,
953
00:37:55,360 --> 00:37:57,160
inserts the backplate and
rails,
954
00:37:57,200 --> 00:38:00,200
and finishes the rivets by
hand.
955
00:38:00,240 --> 00:38:02,520
It's then tensioned and
aligned.
956
00:38:02,560 --> 00:38:06,480
The whole saddle-making process
can take up to 36 hours.
957
00:38:06,520 --> 00:38:08,440
What has that just done, Eric?
958
00:38:08,480 --> 00:38:10,600
That's pulled it one way
and pushed it back the other?
959
00:38:10,640 --> 00:38:11,680
- That's it, yeah.
960
00:38:11,760 --> 00:38:13,720
It's into there now.
961
00:38:13,760 --> 00:38:16,440
- One inspection, yeah,
to make sure it's all right,
962
00:38:16,520 --> 00:38:19,440
and I'm taking this
to the bike factory.
963
00:38:19,520 --> 00:38:21,360
- Good luck to you.
964
00:38:21,400 --> 00:38:23,400
And I hope it lasts you
for years and years, my friend.
965
00:38:28,320 --> 00:38:31,000
[upbeat music]
966
00:38:31,080 --> 00:38:34,760
More than 100 leather saddles
arrive at the factory every
week
967
00:38:34,840 --> 00:38:39,880
and mine is coming straight
into the final assembly
station.
968
00:38:39,920 --> 00:38:44,360
My bike has brakes, wheels,
handlebars, and a chain
969
00:38:44,440 --> 00:38:47,400
and it's almost ready
for the road.
970
00:38:47,440 --> 00:38:49,200
Can you fit this one
cause I actually made this one?
971
00:38:49,240 --> 00:38:51,240
- Okay. Yes, sir.
- I think you can have a go.
972
00:38:51,280 --> 00:38:54,840
It's been 17 hours
since I started this journey
973
00:38:54,880 --> 00:38:59,240
and of the 1,200 parts
that make up this bike,
974
00:38:59,280 --> 00:39:02,000
I am about to tighten
the very last screw.
975
00:39:04,640 --> 00:39:08,920
[upbeat funky music]
976
00:39:08,960 --> 00:39:12,120
- This is a Halfbike.
There's no seat.
977
00:39:12,200 --> 00:39:13,840
You pedal standing up.
978
00:39:13,920 --> 00:39:17,760
But this is one of thousands
of new bike designs.
979
00:39:17,800 --> 00:39:21,320
I wonder if it'll catch on.
980
00:39:21,360 --> 00:39:24,360
The Halfbike was designed
and built in Bulgaria,
981
00:39:24,400 --> 00:39:27,120
thanks to a crowdfunding
website.
982
00:39:27,160 --> 00:39:29,200
The internet has opened the way
983
00:39:29,240 --> 00:39:32,600
to all sorts of weird
and wonderful new bikes.
984
00:39:32,640 --> 00:39:36,280
There are trikes,
like the Outrider Horizon,
985
00:39:36,360 --> 00:39:38,800
or how about
the folding YikeBike?
986
00:39:38,880 --> 00:39:43,800
Or maybe the recumbent
Ratracer?
987
00:39:43,880 --> 00:39:48,680
But not every new bike design
looks revolutionary.
988
00:39:48,720 --> 00:39:50,720
The new generation
of electric bikes
989
00:39:50,760 --> 00:39:53,800
have compact batteries
990
00:39:53,840 --> 00:39:59,560
and the efficient motor
is disguised in the design.
991
00:39:59,600 --> 00:40:05,120
Eddie Kehoe
is an e-bike convert.
992
00:40:05,160 --> 00:40:08,880
It looks like a domestic bike.
What makes it electric?
993
00:40:08,920 --> 00:40:10,360
- When you press on the pedals,
994
00:40:10,400 --> 00:40:12,960
it senses the effort
you're putting in
995
00:40:13,040 --> 00:40:15,880
and then it boosts that
by a certain percentage,
996
00:40:15,920 --> 00:40:18,720
which you can set,
using the up and down arrows
997
00:40:18,760 --> 00:40:20,720
here on your thumb control.
998
00:40:20,760 --> 00:40:22,520
And then it blends
the assistance
999
00:40:22,560 --> 00:40:23,960
with what you're doing
naturally on the bike,
1000
00:40:24,000 --> 00:40:25,960
so it feels very natural.
1001
00:40:26,000 --> 00:40:27,440
- Okay, can I have a go?
1002
00:40:27,480 --> 00:40:28,360
- You can.
1003
00:40:28,440 --> 00:40:29,400
- Oh, wow!
1004
00:40:29,480 --> 00:40:32,280
[upbeat music]
1005
00:40:32,320 --> 00:40:37,000
♪
1006
00:40:37,040 --> 00:40:41,400
Oh, my goodness me!
1007
00:40:41,480 --> 00:40:43,760
It's like you have superpowers.
1008
00:40:43,800 --> 00:40:45,520
- It's brilliant. Bionic legs.
1009
00:40:45,560 --> 00:40:48,080
- Oh, bionic legs!
1010
00:40:48,120 --> 00:40:51,360
- [crowd chattering]
- [crowd laughing]
1011
00:40:51,400 --> 00:40:54,480
We're taking all of our bikes
out onto the street
1012
00:40:54,560 --> 00:40:59,360
to see which one the cyclists
of Cambridge prefer.
1013
00:40:59,400 --> 00:41:01,600
[upbeat rock music]
1014
00:41:01,640 --> 00:41:03,000
What will people make
1015
00:41:03,040 --> 00:41:07,560
of the 350-quid
seatless Halfbike?
1016
00:41:07,600 --> 00:41:08,680
[screams]
1017
00:41:08,760 --> 00:41:10,520
♪ ♪
1018
00:41:10,560 --> 00:41:11,840
What did you think of it?
1019
00:41:11,880 --> 00:41:13,600
- It's good,
a bit difficult at first
1020
00:41:13,640 --> 00:41:15,640
but, once you know
how to do it, it's easy.
1021
00:41:15,680 --> 00:41:17,760
- I like the fact it doesn't
take up that much space.
1022
00:41:17,840 --> 00:41:19,400
It's quite light.
1023
00:41:19,440 --> 00:41:21,360
- Would you swap
a regular bike for this bike?
1024
00:41:21,400 --> 00:41:22,720
- No.
1025
00:41:22,760 --> 00:41:24,160
- But, today, it seems
1026
00:41:24,200 --> 00:41:26,680
that Eddie's two grand
electric bike
1027
00:41:26,720 --> 00:41:31,520
is the clear favorite.
1028
00:41:31,560 --> 00:41:34,760
[crowd cheering]
1029
00:41:34,800 --> 00:41:36,120
- It was like you get on it
1030
00:41:36,200 --> 00:41:38,120
and it just takes you,
you just go.
1031
00:41:38,200 --> 00:41:39,680
Which is fun.
[laughing]
1032
00:41:39,720 --> 00:41:40,760
I didn't wanna come off!
1033
00:41:40,800 --> 00:41:43,200
- It's amazing, honestly!
1034
00:41:43,240 --> 00:41:45,840
- Yeah, it just felt so easy
and comfortable to ride as
well.
1035
00:41:45,880 --> 00:41:49,360
♪
1036
00:41:49,400 --> 00:41:51,360
- Well, they say
you can't reinvent the wheel,
1037
00:41:51,400 --> 00:41:53,520
but I think today has proven
1038
00:41:53,560 --> 00:41:56,840
that there are a few really fun
new developments in cycling
1039
00:41:56,880 --> 00:41:58,400
to keep an eye out for.
1040
00:41:58,440 --> 00:42:02,720
♪
1041
00:42:07,520 --> 00:42:11,320
- At the factory, my folding
bike is now complete.
1042
00:42:11,360 --> 00:42:14,080
It's taken more
than 16 1/2 hours
1043
00:42:14,120 --> 00:42:17,640
for the parts of this giant
bike jigsaw puzzle to come
together.
1044
00:42:17,680 --> 00:42:19,360
[bicycle clanking]
1045
00:42:19,400 --> 00:42:21,160
But before it can leave
the factory,
1046
00:42:21,240 --> 00:42:24,360
there's one crucial stage
it's still got to get through.
1047
00:42:24,400 --> 00:42:26,120
Feel a bit nervous if it's
going through an inspection.
1048
00:42:26,160 --> 00:42:27,840
I've had a hand
in putting every bit on.
1049
00:42:27,880 --> 00:42:30,000
Barney examines every inch.
1050
00:42:30,040 --> 00:42:31,160
- We've got
the right handlebars,
1051
00:42:31,200 --> 00:42:32,600
we've got right gearing,
1052
00:42:32,640 --> 00:42:34,200
we've got the mudguards
on there.
1053
00:42:34,240 --> 00:42:37,240
- Back and front.
- I want you to go like that.
1054
00:42:37,280 --> 00:42:38,280
Do you think
it's gonna fall apart
1055
00:42:38,320 --> 00:42:39,480
any time soon?
1056
00:42:39,520 --> 00:42:41,680
- No!
- It's looking good.
1057
00:42:41,720 --> 00:42:44,440
- And finally,
it's the moment of truth.
1058
00:42:44,480 --> 00:42:46,480
Will the bike I've helped
braze,
1059
00:42:46,520 --> 00:42:49,960
bolt, and screw together
actually fold?
1060
00:42:50,000 --> 00:42:52,040
- If you pull that up
and pull the bike up.
1061
00:42:52,080 --> 00:42:54,560
- We undo this?
- Yeah.
1062
00:42:54,600 --> 00:42:55,960
- Yeah!
1063
00:42:56,040 --> 00:42:57,720
- That should
just fall into place.
1064
00:42:57,800 --> 00:43:00,440
- Now this?
- Yeah, saddle.
1065
00:43:00,480 --> 00:43:01,960
- Happy?
1066
00:43:02,000 --> 00:43:04,280
- I'm just a folding
bike genius.
1067
00:43:04,320 --> 00:43:06,680
- Okay.
- Feel very proud of this.
1068
00:43:06,720 --> 00:43:08,600
- That's it.
1069
00:43:08,680 --> 00:43:10,000
There.
1070
00:43:10,040 --> 00:43:12,840
But I don't get
to keep this bike.
1071
00:43:12,880 --> 00:43:15,120
Along with the 46,000 bikes
1072
00:43:15,200 --> 00:43:18,000
that leave this factory
every year,
1073
00:43:18,040 --> 00:43:20,720
it could be sent to one
of seven cities in the UK,
1074
00:43:20,760 --> 00:43:22,520
from Edinburgh to Cambridge,
1075
00:43:22,560 --> 00:43:25,160
or exported
to one of 43 countries
1076
00:43:25,200 --> 00:43:26,680
across the globe,
1077
00:43:26,760 --> 00:43:28,440
even to the world's
big bike exporters,
1078
00:43:28,520 --> 00:43:30,240
like China and Taiwan.
1079
00:43:30,320 --> 00:43:32,320
♪ ♪
1080
00:43:32,360 --> 00:43:35,320
Following this bike
from parts through to packaging
1081
00:43:35,360 --> 00:43:38,400
has been
an incredible experience.
1082
00:43:38,440 --> 00:43:40,240
It's not what I expected.
1083
00:43:40,320 --> 00:43:42,360
What I expected to find
was an enormous great factory
1084
00:43:42,400 --> 00:43:43,800
with loads of robots
and machines
1085
00:43:43,840 --> 00:43:45,640
and steam coming up.
1086
00:43:45,680 --> 00:43:48,920
Actually, what it is is people,
craftsmen,
1087
00:43:48,960 --> 00:43:51,720
putting these together by hand.
1088
00:43:51,760 --> 00:43:55,000
And all in under 24 hours.
1089
00:43:55,040 --> 00:43:57,040
Hey!
1090
00:43:57,080 --> 00:43:58,320
I don't know
where this is going.
1091
00:43:58,360 --> 00:43:59,880
It could be going to Southend,
1092
00:43:59,960 --> 00:44:01,680
it could be going
to South Australia.
1093
00:44:01,720 --> 00:44:03,960
I hope whoever receives it
enjoys it
1094
00:44:04,000 --> 00:44:06,480
and I hope they appreciate
the hard work
1095
00:44:06,520 --> 00:44:08,640
and craftsmanship
that went into it.
1096
00:44:08,680 --> 00:44:10,320
I put a couple of nuts
and bolts on this one myself.
80743
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