Flying again soon?

Flying again soon?

Just the faintest glimmer of hope that global air travel is starting to pick up again now that the peak of the Covid-19 pandemic is being brought under control. Flights up 10% over the last three weeks.
It’s interesting how the shape of this curve resembles the direct inverse of daily new infections and goes to underscore how quickly airlines cut flights, whether by government decree or market forces.
I’m sure this represents a double-edged sword to all of us – we’re all itching for life to return to normal and, with it, being free to travel – but not until we can be confident that the threat of a second spike is averted.

Lockdown project

Lockdown project

Today we shipped this to a customer in the UK – a complete self-build Ventoux kit in raw aluminium for him to paint/finish. Not something we normally do but the customer seems to be pretty technically minded and was desperate for an excuse to spend hours in the shed during lockdown!

What we do. Photos.

What we do. Photos.

We’re often asked where and how our boxes are made.  More time in the home office currently has provided time to share some images that help to tell the story.

Our boxes are assembled in Okehampton, Devon – but that’s just the final point of call for the 148 components and 646 rivets that go in to a Tourmalet box – much of the value is added further upstream the in the supply chain, with as much material as possible sourced locally.

As an example, we’ll look at the ten panels that make up the sides of each box. Made from a high-strength aluminium alloy, these are rolled to a 0.5mm thickness in the USA, stocked as sheets by an aerospace material broker in Cornwall, then laser-cut in Plymouth and screen-printed near Exeter before delivery to us.

Having these suppliers so close helps to keep lead-times for standard boxes down but, more importantly, gives us rapid access to the type of one-off parts that are so important in being able to offer custom sizes and features.

The following images take a closer look at the printing of the panels and the final assembly of complete boxes, all performed in small businesses by skilled craftsmen.

The graphics you see on the standard Tourmalet and Ventoux boxes are applied with a traditional screen-printing process – super-tough epoxy ink is applied in two stages, black and green, directly to the aluminium substrate. This is a job that requires precision and patience – there is no second chance with these inks… The resulting finish is highly scratch resistant and is able to withstand the best efforts of the most careless of baggage handlers!

Final assembly is all about rivets, many thousands each day. Printed panels and anodised extrusions and laid out and aligned on assembly jigs made from machined beech before being joined with four sizes of special closed-end rivets. Each one of these are incredibly strong – even the smallest size used could suspend the weight of two average cyclists. With more rivets per square metre than a Boeing, you can see why these boxes are so strong. Final assembly of each standard box typically takes three hours – custom designs can easily be double or triple that…

I hope that helps to answer a few common questions – please don’t hesitate to contact us further here about anything else.

Special thanks to Simon Edwin at Studiose for providing the photography – Studiose were behind the recent revamp of box graphics and website updates. Printing is by Optima Graphics. Both are highly recommended.

Rivets, rivets, rivets. Four sizes, super-strong

Screen-printing requires a deft touch

The print squeegee and screen – traditional printing methods live on!

Raw panels straight from laser-cutting – cutting this would take less than ten seconds

One printing pass down, one to go – green stripes are printed over main black graphic

On the rack for 24 hours of curing

This print head has seen some life…

Just two of the 148 aluminium parts that make up a Tourmalet box

Corner caps anyone? 100% airline-proof

Machined beech ply assembly jigs for speed and precision – also made in Devon

Assembly jig for Tourmalet end panel – pliers for artistic effect!

Ventoux end panel aligned with assembly jig

Populated with rivets

More rivets – we use a lot of these! And a second life for a tea tin…

Hydro-pneumatic rivet guns from Japan make light work of these

Perfect alignment – tolerance between rivet holes is just 0.1mm

Nearly done – these side panels can now be mounted to the chassis of the box

Just saying…

Lowers waiting for uppers – the uppers only take half the time of the lowers to build

The finishing touch


We’re still here…

We’re still here…

In these times when flying away with your bike seems, at best, rather frivolous, I’d like to express sincere thanks to customers and suppliers alike for their continued support – never has it been more clear that we’re all in this together.


We’re still here – currently working our way through production of March orders. Social-distancing precautions mean that everything is considerably slower but we’re nearly there.


A note to anyone in the UK involved in the manufacture of equipment involved in fighting Covid-19, we’ll soon have production capacity for sub-contract light assembly – offered on a not-for-profit basis. Please contact here or via the website form.


Best wishes. Stay safe.





Photograph courtesy of Studiose



Buxumbox Ventoux and Tourmalet – slight seconds sale

As many of you know, we moved in to a larger unit last month – we’re now settled in to the new facility and running production at full bore.

There were some minor casualties during the move though – a number of the screen-printed panels that are built in the boxes suffered very minor scratches and/or scuffs. We’re talking very minor – not even enough to create a dent or scratch the substrate aluminium.

This does mean that we can’t sell them as first quality product and hence we’re going to build these up and offer them for sale at a 10% discount on a first-come/first-served basis. We have:

  • 2x Ventoux (can be built to Road or MTB spec)
  • 2x Tourmalet H1
  • 1x Tourmalet H2
  • 1x Tourmalet H3

If this is of interest, please contact us via form on website or Facebook.

Super-stretch custom Ventoux MTB box

Super-stretch custom Ventoux MTB box

Here’s a good example of a custom box – based on the Ventoux MTB but stretched in length and height to accommodate a XL size Pole Stamina with a 136cm wheelbase. This Canadian customer also wanted mounting brackets so he could use the box to ship his Trek Domane.