What does it take to make the finest titanium bikes in the world? This quick tour of the Merlin factory should help to answer that. The following pictures will make it easier for you to see the dedication to impeccable quality that makes Merlin and Litespeed the very best.

Hopefully it also illustrates why (given the materials, time, craftsmanship and care that go into every Merlin and Litespeed Ti frame) a great Titanium frame may cost a few dollars more than a carbon frame born in a mould.

How it all begins ~

30 foot tubes of genuine Haynes seamless aircraft certified titanium tubing, the finest there is.

Some of the shaping machinery ~

Custom shaped tubings ~

All done in-house, all seamless!

Completed precision miters ~

Merlin has the closest tolerances of any frame in the world today. The fact is Merlin set the standards that all other serious builders now strive to match.

Solid titanium bottom bracket stock ~

Only Merlin takes the time to do this kind machining! The precision of the bottom bracket cut determines the precision that the rest of the frame can be held to. Skimp here, as every other builder does, and the most you can hope for is second best!

Finishing tools for bottom bracket ~

This is one amazing machine! To the right, under a constant fluid batch, all the various steps of machining are actually done. What you are seeing is the assortment of cutters and bits that the hydraulic arm will reach up and grab between each step of the machining process.

Cutting the solid core bottom bracket ~

Here is the cutter going to work. Note the constant fluid bath. The bath lubricates, controls heat, and clears away the cutting residue.

Completed bottom bracket welds ~

How is that for precision! No grinding and hiding needed here.

Frame specific seamless Haynes tubing ~

Each tube on every size of each model is artfully shaped, inside and out, to guarantee the world's finest Ti ride. No other builder approaches this kind of precision or attention to detail. Size specific tubing is one of the prime reasons that no other builder approaches the Merlin ride.

Perfectly mitered head tube joints ~

This picture is from a random frame in production. Each and every Merlin meets this same standard of excellence.

Completed head tube welds ~

Once again, a random frame in production. Every frame receives this same state-of-the-art weld quality that has made Merlin a legend around the world.

Machine tools for all the small parts ~

Not satisfied with production parts, Merlin makes every little bead and bauble in-house!

Weld-ons all made in-house ~

Speaking of beads and baubles, here is what it takes to build a frame!

Welding jig ~

Each frame is individually jigged for precise alignment that is built right in, not pried in later.

Starting the welds ~

No robots here! A master craftsman handles each and every detail at his or her personal welding station.

Welding the head joints ~

Pictures of the wife and kids adorn most of the stations.  

The finished weld stack!  ~

A 24 step inspection routine then onto the finishing rack.

Applying decals ~

Once again, only time consuming handwork by a master artisan can meet the standards that every Merlin rider deserves. 

The glorious finished rack! ~

Can you say "lust"!?