Yesterday Morewood Engineering began powder-coating the first batch of Zula frames destined for the patient South African customers who had their names down on the very first batch of the Zula production. These lucky, soon-to-be Zula owners will be receiving their bikes VERY soon as the hands and powers that be in the Morewood factory are frantically doing the final assembly, QC, prep, alignment and packaging of these beautiful pieces. Check out the little gallery and story below and watch these frames come to life…

All of the tubing which is used on the Zula and Kwela frames is proprietary to Morewood: Patrick [Mr Morewood] and Fabien [their French design engineer] have spent many nights and days going back and forth, running FEA tests, dealing with suppliers, testing and prototyping to get to the final product: the tubesets which each of these frames use. Each of the tubes are drawn, butted and then pressed [NOT hydroformed] to their final shape. After this they are carefully inspected and sanded smooth by hand in order to ensure the smoothest, finest finish.

The tubing, once passing through all of the processes mentioned above, is then processed and made ready for the next stage in the production cycle: cutting and mitring. In this process the tubes are cut by machine [some using laser] to length with all of the various shapes and angles needed in order to fit together correctly before they can be transferred to the welding department for welding. Morewood take care of all of the mitring and cutting of these tubes in-house on specially made and modified machinery, cutting out the reliance on other parties and ensuring that quality standards can be met by their own skilled workmen and women.

The Zula features a few new idea’s and design concepts for Morewood, the most striking of which is obviously the swingarm box; replacing their characteristic design of CNC machined swingarm plates, Morewood has refined their design significantly on the Zula and uses a svelte, ultralight and incredibly stiff box which is lazer cut pressed and formed to shape before being welded together. This process is also used on the shapely seat-tube gusset seen on the left. In addition to this process, these parts also feature a new welding technique employed by the Morewood welders where the welds are carefully smoothed to give a more aesthetically pleasing finish where the two pieces are joined.

The singarm tubes, seen on the right, also pass through the same drawing, butting and forming process as the top and down-tubes, in addition to this the seat-stay is bent using a CNC bending machine. This one-piece seat-stay locates perfectly into the swingarm box adding further to the uniqueness and significance of the frame design. Despite what many may think on first appearance, the Zula is somewhat unique as a single pivot as it employs a drop-chainstay design whereby the chain runs over the chainstay THROUGH the swingarm. This increases the triangulation of the swingarm improving its overall stiffness as well as allowing flex where needed to increase the durability and fatigue-life of the frame.

Once the down-tubes have been cut and mitred to length they are sorted into sizes and then cable-guides are fitted as well as the rivnuts for the water-bottle cage. The Zula, available in 4 sizes: small, medium, large and extra large, is able to fit a water bottle into the triangle of ALL frame sizes making it an ideal frame for longer, multi-day events where hydration is imperative. If riders wish to mount an additional water-bottle however they will need to mount the bottle behind their seatpost. Something else to note is the cable-routing on the Zula, both brake and derailleur cables run neatly along the down-tube of the frame in a continuous format meaning there is less likelihood of contamination.

Again, evidence of its commitment to offer premium product, Morewood CNC machine all of their own plate for swingarm plates, dropouts, shock mounts and even machine their own derailleur hangers. Morewood do all of their CNC programming themselves and most of the jigging is designed and made by Patrick in order to improve efficiency and keep production flowing as smoothly as possible. Regardless of the time of day or day of the week it is very rare when the CNC machine at Morewood is sitting idle, this machine clocks up a significant count of work-hours, and its handlers, programmers and operators all ensure that the output is the best, most accurate it can be.

Morewood employs 3 skilled and dedicated welders, each of these welders work tirelessly to produce sufficient frames each month to meet the demands put on Morewood by its consumers world-wide. Distributing to 28 country’s is a big task and requires a significant amount of time, effort and work to make sure lead-times are met and customers are happy. Added to this the stress of knowing what rigours their bikes are put through, the welders have a tough task. Whats more is that hiding behind their masks Leon, Russell and Charl get little credit for their time and labor. Every Morewood owner ought to know that these three people had a significant part in making the frame which you love to ride.

How many people think the frame which they are riding is straight? Every single Morewood frame which passes through the factory in Pietermaritzburg is carefully checked, tweaked and straightened throughout the welding process and again after annealing during the heat-treatment process. This time consuming task ensures than when frames are finally assembled they are as close to perfect as possible. This hands on approach also gives the frame its characteristic ride, look and feel, and its this same attention to detail that Patrick and his crew employ that makes their product truly special, and truly South African.

My Excel spreadsheet of customers who have placed Zula frames on back order doesn’t seem to be getting any shorter, and the rate of its growth doesn’t seem to be slowing either. So here is a interesting thought: by the end of December the number of Morewood frames in the South African market would have doubled! Doubled from what? Well by the end of December there will be more Morewood frames in South Africa than ever sold over its 8 years of producing and selling frames. This to me, coupled with the constant compliments and congratulatory emails and phone calls which I have received, speaks louder than anything. For the first time in eight years the South African consumer is noticing this little company in Pietermaritzburg who have been tirelessly designing, racing and producing frames for customers all over the world. For the first time many people are embracing what is South Africa’s ONLY truly South African bicycle! I thank you all from the bottom of my heart! I hope that each and every Morewood sold brings to its owner a sense of pride in owning something truly unique, truly South African and truly special.

Now if I could just get my hands on one…

Happy trails,

Andre

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