From Frame Building Course to His Own Workshop: Gerald’s Path to Building Bikes

From Frame Building Course to His Own Workshop: Gerald’s Path to Building Bikes

Many people who take a frame building course wonder: Can I really continue on my own afterward? Gerald is the perfect example that it’s possible! He attended one of our courses in 2021 and built his first custom bike—check it out here. Since then, he has continued crafting steel frames in his own workshop. In this article, he shares how he got into frame building, why he chose his latest frame design, and how he brought it to life step by step. A fascinating look into the journey of a passionate self-builder!

Gerald – How did you hear about Big Forest Frameworks’ frame building courses?
I took a course with Robert in 2021 and learned a lot. He really shares his knowledge, and I think that’s fantastic. Something just clicked for me, and I knew I wanted to keep going. I started designing my own frames, invested in my workshop setup, and kept learning by experimenting and watching YouTube videos. I’m especially hooked on Paul Brodie—he’s a real expert in this field.

How did you get the idea to build your own frame?
The “Steel Race 04” is already my fourth bike, as the name suggests. I’ve been building bikes for years. I’ve always been interested in craftsmanship, and frame building is the perfect combination of my love for cycling, traditional handiwork, and a balance to the stressful digital world. I’ve built carbon and bamboo frames before, but right now, I’m really into steel.

Last year, I invested heavily in my own workshop—frame jig, lathe, tube notcher, oxy-acetylene welding setup, software, and all the tools you need to build a frame. It was absolutely worth it—I’m really happy with the results.

Why did you choose this particular frame?
My last bike was a gravel/bikepacking bike. It made sense to replace my aging road bike with a new one—of course, made of steel again. I wanted modern geometry, the best tubing, and top-tier components. My motto: “You might as well treat yourself!”

Is there anything special about the frame?
Yes—everything! First, there’s the oversized 44mm Columbus Spirit down tube—top quality. Then, the combination of different tube sets: a Life top tube and a Zona seat tube. That means lightness and stability in one.

Then there’s the very special T47 bottom bracket—Robert could probably write a whole scientific paper about it. I think this oversized bottom bracket is a real game-changer. Its larger size gives you more freedom when attaching the chainstays, allowing for bigger tire clearance. At the same time, it lets you route cables—or, in my case, electronic shifting wires—internally, keeping them hidden and protected. Despite its size, it doesn’t look bulky because the internal bearing cups keep the crank width the same.

Finally, I took on the challenge of using a tapered head tube. Of course, that means manually filing every tube junction until they fit perfectly. But with BikeCAD’s templates, that process is super precise.

Did you have someone else do the finishing on your frame?
No, I also invested in my own painting setup. That way, I can create custom designs that take a lot of time but cost very little money. I found the current paint design online and tweaked it slightly. The bike features four base colors that transition in a line from the fork to the rear triangle. I even sanded down and repainted the high-quality Columbus fork to match the frame’s design.

How does the finished bike ride?
Winter has limited my test rides so far, but the first outings have been very promising. It rides smoothly, silently (no rattling!), stiff yet compliant. That’s the magic of steel!

I also installed a Campagnolo Super Record EPS groupset. The internal wiring made the installation a bit tricky, but I’m seriously impressed with how fast and precise the shifting is.

What’s next for you?
Friends have already asked me to build bikes for them, so that’s happening! I also run workshops on bike repair, so maybe one day, there will be a frame building course in Tirol! Just like Robert’s setup in Berlin, I think it would be a great fit for an active vacation in the mountains.