Video: The 77designz Bike - From Prototype to Product

Jul 31, 2019
by Giacomo Großehagenbrock  

Words: 77designz


It all started with a passion project of our mother company 77designz. We wanted to build an enduro bike that delivers uncompromised performance. No market studies, no marketing bull shit, only serious engineering straight to the point of making the fastest enduro bike we can imagine.

The goal was to design an enduro race bike that climbs like an all-mountain bike(high anti-squat, steep seat tube angle) but descends like a downhill bike (rearward travel, no pedal kickback, long and slack, low BB). In order to achieve the highest performance, we knew that we need to go down the high pivot point road. There was one thing bothering us with that and it was the high anti-rise that usually comes along with high pivot point bikes.

We wanted a bike that conserves the geometry and offers enough traction under braking and also has massive support under pedaling but no pedal kickback. As soon as we figured how we had to design the kinematics in order to keep the anti-rise low (80%) we were ready to get the party started.

For a little more on the backstory, check out our first three articles on developing, manufacturing, and testing the bike up to this point.

The Kavenz VHP16

We designed with the rule of simplicity in mind. Straight lines no unnecessary weight or shape. We believe round and straight tubes still do the best job in terms of stiffness too weight ratios and also they hold strong against impacts.

Testing the first prototype in Squamish / BC

After one year on the prototypes and many exited people who tried the bike, we decided to improve the design towards a production-ready product and go the route of becoming a bike brand. The name we choose, 'KAVENZ' originates from the German word Kaventsmann which means 'Monster Wave' or strong and reliable person in our local slang (Masemate). As we are proudly going to weld the frame with bespoke geometry options in Germany, we found that the name suits us well.

Assembly:

The bearings are oversized and secured with retaining rings.


The idler pulley is where the magic happens.

Super clean yoke with almost no surface for the mud to stick.

Simpicity at it´s best - KAVENZ VHP 16

We are not ready to launch yet as there are still some steps to take. We have a lab test where we want to achieve Category 5 (DH Level) certification and some tuning camps so we can deliver the frame with perfectly tuned suspension. If things go smooth, we plan to accept orders in autumn and deliver the first frames in early spring (first come first serve). For us as a small brand, this is a big step up of our game so every step has to be taken carefully in order to deliver a perfect product on time. We also take encouragement from all of your positive comments here. Thanks for your love, it definitely keeps us going and is what pushed us to become a bike brand.


MENTIONS: @Giacomo77



124 Comments

  • + 47
 This is super exciting! Looking forward to Pinkbike's First Ride Smile
  • + 44
 Thanks, once we are production ready we will offer it to the pinkbike crew!
  • - 11
flag RedBurn (Jul 31, 2019 at 6:09) (Below Threshold)
 @Giacomo77: offer really? Big Grin
  • - 23
flag TrevZ (Jul 31, 2019 at 6:26) (Below Threshold)
 Super exiting*
  • + 13
 @TrevZ: not really, no.
  • + 2
 @Giacomo77: well done
  • + 2
 @jlague: thanks
  • - 9
flag jorgeposada (Jul 31, 2019 at 9:38) (Below Threshold)
 Everything looks sick but the logo is like something my nephew would design on his phone for his next metal band.
  • + 1
 Will be nice if they apply some grease before they fit any bearings! At some point you will have to replace them and then surprise , they stuck like F@.k
  • + 2
 @allbiker: the bearings are completly pre greased.
  • + 6
 @jorgeposada: taking preorders for a bike that won't be delivered for 6 months long after PayPal and other protections are gone..does sound rather SICK to me.
And that fiasco is still fresh in my mind.

Hey PINKBIKE why don't you tell everyone how the Sick bicycles story ended for their customers?

You gave them a platform to lie on multiple occasions and reign in more suckers. So let's wrap that story up.
  • + 5
 @jorgeposada: I like the logo so let me know when your nephew's album is out. Not sure what kind of metal it is but I'll give it a listen.
  • + 2
 @jorgeposada: please show us your new bike with its awesome logo. If not......shut up!
  • - 7
flag jorgeposada (Aug 1, 2019 at 1:56) (Below Threshold)
 @Cashman39: Show me a picture of your mother then stick it up her ass then shut up, feel me.
  • - 4
flag jorgeposada (Aug 1, 2019 at 2:29) (Below Threshold)
 @underhawk: Which band, he is in like 15 and plays everything from noise to thrash metal all over NYC? Actually most of his logos are way better than this one.
  • - 3
 @reverend27: Exactly one of the many reasons I would never consider buying this bike.
  • + 28
 I like it. But...marketing it as non marketing bullshit, is still, well, marketing bullshit, and that's just bullshit marketing.
  • + 39
 Made me smile, of course it is marketing but is a transparent documentary about a development process marketiing BS?
  • + 25
 Marketing (+1) as non-marketing (-1) is still marketing (+1) which is BS (-2) marketing (+1).

Final tally = 0 marketing points. You're in the clear, 77!
  • + 14
 @MTBrent:

Agreed I found my mistake

What I wanted to say in the article is = No Marketing BS Kinematic which looks new but has nothing new to offer, and it´s only purpose is to sell the bikes easier to the customer because of its unique selling point which does not make it a better bike.
  • + 1
 @jason475: I see what you're saying but @Giacomo77 @Kavenz are the most down to earth guys who just want to provide/build the best bike possible. The Kavenz VHP16 is the best bike I've ever ridden. Their 77designz products are also simple and faultless. I'm a massive fanboy.
  • + 2
 @Cashman39: >
I like the bike and I dig what they are doing. I also really like their "simplistic" approach. I hate overly complicated things, especially with bikes. I was just making up some marketing bullshit. You know, sarcasm.
  • + 19
 Gunmetal grey + orange spring = take my money
  • + 7
 It's a beauty!
  • + 13
 If you’re serious about simplicity ditch the internal cable routing. It definitely creates totally unnecessary complication.
  • + 10
 Next - Learn how not to get Sick.
  • + 6
 Frame looks perfect!! I like minimalistic designs. Best wishes for your start as a bike manufacturer! ... and please stay rooted when you develop Smile We already have big players with bad costumer service and questionable employee treatment... Wink
  • + 1
 *customer Big Grin
  • + 8
 looks awesome. i love seeing new bikes in alloy.
  • + 7
 Yes G!!! So happy to see you living your dream! Killer bike from the most rad guy in the industry!
  • + 3
 Thanks mate ;-)
  • + 7
 Also love the straight down tube. No need for that bend to catch every rock/log strike
  • + 4
 I ride a pre-production frame (510mm reach) with EXT-Shock and its fast AF . Coming from a Nukeproof Mega 290 (515mm reach): it cornes much better (shorter cs, in tight turns), it pedals better (STa), Kinematics are on point, no drag/noises (when chain is properly lubed). See my photos Smile
  • + 4
 One of the better and more interesting looking frames out there. Really well done on the aesthetic and It'll look even better Raw. These videos are cool and it's always nice to see the face behind the name like Starling has done on their Instagram page. Cool shit, best of luck! Gans geil!
  • + 2
 cheers mate, we would call it richtig geil ;-)
  • + 2
 Looks soooooo good luck with your project! One note... If hammering on bearings you plan to continue using, make sure the drift seats on the outer race, as if hammering on the inner race you will create small dents in the rolling surfaces.
  • + 4
 He mentions at minute 3 that the spacer being used to hammer the bearing into place only contacts the outer race to protect the bearing.
  • + 2
 @fnuss: AHHH perfect I missed that thanks!
  • + 2
 @Giacomo77 what shall I tell you? from what I saw you entered my list of favorites, as an Italian I already, ti amo, only for the frame Wink .
If I can I would advise you to try with the raw frames in order to highlight the welds that seem to me very good, moreover even if I am not mechanically exposed I would try to work the central block differently in order to eliminate the vertical welding, maybe doing it as a CNC by welding it later the bearing housing.
Take care of the accuracy of the alignments and pay attention to the details, add a description of the geometry and kinematic characteristics and you are fine.
Good luck, good is how you create something not simply buying it already made in asia.
  • + 3
 This pretty cool guys, well done. Great to see behind the curtain. Your transparency on here about design is pretty awesome too. Cheers
  • + 1
 Love the design. Would it be much more difficult production or something else wise to make the headtube wide and use different headset chips for different reach options? A la propain?
  • + 6
 It´s realy not easy to make that work proper and we can offer any reach option you want from 440 to 540 in 10mm steps so there is no need to that for us. If you have to invest in carbon molds it makes sence to do it the other way.
  • + 1
 That frame looks really cool. I like the video because I like detail and knowing the thought process behind design choices. Good for you guys! Probably too soon to tell but will you be selling to Canada?
  • + 1
 I like the idea and design, but you better be fast or the high-pivot hype will be ovr before you hit production and we have "the next new thing" that is 24% better than everything we had before Smile
  • + 1
 @Giacomo77 I didn't see the design video yet (but I'll take a look later) but what is the reasoning behind the idler pulley not being in line with the pivot?

Frame looks really nice.
  • + 4
 Glad you like the frame, the instant center of the frame is somewhere rougly located beetween frontwheel and lower tube and than moves down towards the BB when suspension gets loaded. The position of the Idler pulley is chosen in a way that results in high anti squat in the SAG postion and let it drop right after to kill any pedal kickback.

Check this video and you´ll understand it better: www.instagram.com/p/BjdppQrBB8J
  • + 4
 Hope they put in the ISCG05 tabs before releasing the bike!
  • + 2
 +1 for the ISCG mounts please! Not all of us are into this new trend of just riding up fireroads and down flowy jump trails; some of us still like to crawl over logs and bash through rock gardens. Chain guide and bash guard are a 100% must for me.
  • + 3
 No worries we have an interface at the BB that takes on the ISCG 05 mounts which than get locked with the BSA shells.
We know that the riders we are targeting with this bike need a chain guide and a crash plate.

You can see it here: www.instagram.com/p/BjxifqyhMvv
  • + 1
 @Giacomo77: Very cool! I was wondering what those notches in the BB were, and now I know. Thanks for the reply.
  • + 1
 I loved my k9 DH bike. I'd love a high pivot trail bike but would be a bit apprehensive about the amount of drag generated by the idler
  • + 3
 In fact none of the testriders could notice the drag. I assume that on the road or with very light XC tires you can feel it but at this maschine it´s hard to fell any drag as most energy goes into the tires anyways right?
  • + 2
 A beauty of a frame! ???? and if it holds up to what its promise it would be a absolute unique stunner! so take my money!!!
  • + 1
 Nicely done. Could bei serious fun out in the trails. If you ever come to Freiburg. Let's go Ride. I want to see that beast in action.
  • + 2
 Cheers buddy, ask Schnetti for ride he is alrready smoking the trails in Freiburg on it´s kavenz!
  • + 2
 I love the look of round tubes. So nice and clean looking. Though I am not the biggest fan of the high pivot..
  • + 3
 You have to ride it to love it.
  • + 4
 Might want to try the high pivot with the Horst link. Best of both worlds
  • + 0
 @cuban-b: it is a horst link
  • + 2
 @Bhaack: With a high pivot...
  • + 1
 @stumphumper92: function over fashion.
  • + 1
 @Giacomo77 everything is looking great at this point. I’m curious to see the solution developed for the brake caliper mount.
  • + 2
 Thanks, there is nothing special with the rear brake mount it´s an old fashioned IS2000.
  • + 2
 I see it now, nicely tucked away.
  • + 1
 @Giacomo77 Looks awesome. Glad to see some English sub-titles so we can follow along.
  • + 1
 i always thought it's " Karl-Jensmann" you should rename the brand to Karl Jens please.
  • + 1
 Looks ace.

I’d hit it.

Need to see the Geo numbers to see if it’s avente grade enough
  • + 1
 Glad they went for e-stay design, but sorry dont have spare cash other wise would be forced to buy one!
  • + 2
 Is that bike come with shtrudel?
  • + 3
 No but with Eisbein
  • + 1
 Looks fantastic. Congratulations guys. Are these going to be super expensive? Or are you looking to to ne a value optuon?
  • + 5
 Going to play in the high end, custom geo, made in Germany and small boutique bike brand game.
  • + 1
 @Giacomo77 What's the ballpark price of the frame (without shock I assume)? I'm liking this a lot. Sehr Geil
  • + 3
 It´s going to be about 2000 € (Excl. Tax) for the Frame in Raw without shock. Detailed prices for colors are and shock options will be anounced later.
  • + 1
 @Giacomo77: Excellent, thanks!
  • - 1
 @Giacomo77: So between $3500-$4k CAD for a frame & shock? LoL
  • + 1
 @m1dg3t: For what it's worth, this is comparable pricing in USD to other boutique frames. The pricing will also depend on where the frame is made and quantities.
  • + 0
 @fudgedredd: Well then,that's quite alright. Why not make it more 'boutique' and slap an extra $500-$1k? It'll have more prestige. LoL
  • + 2
 @m1dg3t: It's basic economics and nothing more. Price is controlled by materials, processes, quantities, country of manufacture and demand. I highly doubt that they would just "slap" extra on for "prestige". Remember, when they order materials, lower volume orders are much more expensive until projected quantities increase. "Boutique" means lower volume and high quality, generally speaking. Look at PUSH. They sell 11-6 at $1,200.
  • + 2
 Beautiful!
  • + 1
 Mmmh, german engineering!
  • + 1
 Wish I could afford a new frame right now!
  • + 2
 Nice.
  • + 2
 10/10 would ride!
  • + 1
 if there will be an option of a raw finish, sign me up!
  • + 3
 We will offer the frame in Raw
  • + 1
 Are you accepting applications yet? Wink
  • + 1
 Not ready jet let us first finish testing and finalize all details, if things go smooth we will accept orders in fall.
  • + 1
 Well done guys, best of luck !!
  • + 1
 Probably the price is around 8-9k
  • + 1
 It looks good but how does it ride?
  • + 4
 Amaaaazing
  • + 1
 @Giacomo77: I'm 30 minutes from pisgah, send me an xl and I'll let u know
  • - 1
 Prolly like most other Horst link + high pivot combos.
  • + 1
 @Bman39: I can personally tell you as a 'tester' it's the most brilliant bike I've ever ridden. I've been riding one of the early prototypes for nearly twelve months and there's nothing this bike cannot do. It's really a dream to ride.
  • + 0
 @Cashman39: What else would you say about it? LoL
  • + 1
 @m1dg3t: I understand your scepticism but understand this, I wanted to be able to keep the frame after testing so I actually paid for it!!!!
People will only be letting themselves down if they don't buy one. I'm not an employee nor do I get paid for my comments. Just a fan.
  • - 2
 @Cashman39: Oh, yeah? That's nice. Congratulations? LoL
  • + 1
 Why is there no pictures of the bike built up?
  • + 2
 Because that is for the upcoming video. But on Insta and Facebook you´ll find some #kavenz
  • + 2
 ALU aint dead!
  • + 1
 What made you ditch the suntour set up you originally had?
  • + 1
 I was happy with SR Suntour but we want to test all options before we decide what to offer.
  • + 1
 @Giacomo77: fair play buddy, would you give Xfusion a try?
  • + 1
 Looks like a cool frame, be great to see how it performs
  • + 1
 Wondering why you haven't put 4 bearings at the main pivot too?
  • + 9
 Because the load is only half as big. 2000 Nm at the rear wheel result in 7600 Nm at the Rocker but only 3000 at the main pivot.
  • + 1
 Is very German to feel an impuls, you cannot resist, that makes you want correct the Nm to N?

By the way: thank you guys a lot for sharing this project with us. I really like the result and your explanations really helped me with my own Frame build!
  • + 5
 @JokerT: sorry mate I must have been drunk already ;-) Of corse its Newton
  • + 1
 @Giacomo77: aaah, never thought of that! Keep up the good work!
  • + 2
 Want!!
  • + 2
 Geile Sache!
  • + 1
 zack.......zack........zack......now you ready for ride!
  • + 1
 Geo, please.........
  • + 2
 You can find it here www.pinkbike.com/u/Giacomo77/blog/77designz-develops-a-bike-frame-production.html
Only the seattube angle changed to 77,5°
  • + 1
 fuck yes
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