How We Build Bikes

All Guerrilla Gravity frames are designed and built in-house here in Colorado. This holistic structure allows us to link all aspects of the design and fabrication process, maintain keen quality control, and provide riders extensive customization options. Here is a photo tour of the manufacturing process:

Our fabrication area.


All aspects of the design and manufacturing are inter-connected, even starting with the base tube and bar stock. By eliminating waste in the mitering and CNC process, we're able to help control costs, passing the benefits on to the riders.

Raw aluminum stock.


Every cut on each model is jigged to ensure a repeatable accurate cut. Once the jig is setup, we are able to batch-cut the tubes, increasing volume and improving efficiency.

The top tube and down tube jig, indexed for each tube and size.

Accurate, repeatable cuts for precision tube fit-up.

Batch-cut, but not yet de-burred, chainstay stock.

Vent holes are then drilled into each tube.

In-house CNC machining.

Pivot box shell halves, machined in-house.

Pivot box shell halves, machined in-house.


After all of the tubes are prepped and parts machined, they are ready for fit-up. Any discrepancies are caught and remedied at this stage, one step in our unique quality control measures.

Welding the pivot box in its jig.

All frame parts secured in the jig, ready for welding.

Precision fit-up improves strength and increases durability.

Precision fit-up improves strength and increases durability.

Rear triangle parts in their welding jig.

Each jig is specifically designed for its intended use.


With over 20 years of experience, Kevin is a master welder, creating both beautiful and strong welds.

Welding the head tube.

Welding the head tube.

Welding the bottom bracket shell.


Once welding is completed, the frames are cleaned, reamed, and prepped for powder coat.

Cleaning the frame of residue from welding.

Hand cleaning the areas the air tool cannot reach.

Post-weld reaming provides an accurate final fit.

Threading the bottom bracket avoids the creaking of the press fit style.

Seat tube reaming is performed on the lathe.

Hand hammer punching of the serial number.

Bottom bracket with the finished serial number.

Frame prepped before being delivered to the local powder coat shop.


Frames are then assembled and checked to ensure all qualities are within tolerance.

Pressing bearings.

Pivot axle installation.

Installation of suspension linkage.

Connecting the linkage to the rear triangle.

Checking to ensure all modes work.

Next stop: your local trails.

Frames are now ready to be outfitted with components and built to the desired specifications of the next rider.