The making of a FERN.
FERN Bicycles — The making of a FERN., workshop photograph by Bengt Stiller.
BERLIN-LICHTENBERG / AT THE WORKBENCH.
Photo: Bengt Stiller

INSIDE THE WORKSHOP

The making
of a FERN.

From the outside, it might look like just nine little tubes, but there’s a lot more to making a frame.

Each FERN bike is built with a lot of knowledge and precision and, most importantly, with love and passion. Come inside and have a look.

Before the first cut.
FERN Bicycles — Before the first cut., workshop photograph by Bengt Stiller.
FERN Bicycles — Before the first cut., workshop photograph by Bengt Stiller.
FERN Bicycles — Before the first cut., workshop photograph by Bengt Stiller.
FERN Bicycles — Before the first cut., workshop photograph by Bengt Stiller.
FERN Bicycles — Before the first cut., workshop photograph by Bengt Stiller.
A BICYCLE BEGINS ON PAPER.
Photo: Bengt Stiller

01 / THE DRAWING

Before the
first cut.

Looking through all the data we’ve collected, along with your bike fit, your ideas, your wishes and your needs, helps me put myself in your shoes. I then condense all of that in the final drawing of your new FERN.

Careful planning and thinking through all the options might be even more important than the actual framebuilding. Only when everything makes sense and all the pieces fall into place is it time to step up to the workbench.

Tight gaps. A lot of attention.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
FERN Bicycles — Tight gaps. A lot of attention., workshop photograph by Bengt Stiller.
TAKING TIME OVER THE CONNECTIONS.
Photo: Bengt Stiller

02 / FIT & PREPARATION

Tight gaps.
A lot of attention.

Cutting, fitting, filing, checking. Then filing and fitting again, until it fits just right. The preparation is a big part of the work.

Working by hand gives me the chance to look closely at each joint and work to the tightest possible tolerances.

Now it starts to look like a frame.
FERN Bicycles — Now it starts to look like a frame., workshop photograph by Bengt Stiller.
FERN Bicycles — Now it starts to look like a frame., workshop photograph by Bengt Stiller.
FERN Bicycles — Now it starts to look like a frame., workshop photograph by Bengt Stiller.
FERN Bicycles — Now it starts to look like a frame., workshop photograph by Bengt Stiller.
FROM SEPARATE TUBES TO ONE FRAME.
Photo: Bengt Stiller

03 / JOINING THE PIECES

Now it starts
to look like a frame.

Once all the pieces fit, it’s time to join them. What began as an idea and a simple drawing starts to become real.

I carefully prepare and clean each tube and joint. Then it’s time to tack the frame together and start the welding.

The art of joining tubes.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
Welding and brazing a custom steel FERN bicycle frame in the Berlin workshop. Photo: Bengt Stiller.
CAREFULLY FITTED. JOINED BY HAND.
Photo: Bengt Stiller

05 / WELDING AND BRAZING

The art of
joining tubes.

Once every tube fits, it is time to make those separate pieces into a frame. Welding and brazing each have their own rhythm, and both depend on the care that went into the preparation.

Heat, filler and a steady hand: this is slow, focused work. I keep checking the details as the connections take shape, until all those individual tubes become one bicycle frame.

An unpainted FERN custom steel bicycle with drop handlebars, an ALLYGN M.U.D. Fork and a rear rack in the Berlin workshop.
FERN custom bicycle assembled in the Berlin workshop, showing the complete build and components.
FERN custom bicycle assembled in the Berlin workshop, showing the complete build and components.
FERN custom bicycle assembled in the Berlin workshop, showing the complete build and components.
FERN custom bicycle assembled in the Berlin workshop, showing the complete build and components.
BUILT HERE. RIDDEN EVERYWHERE.

06 / THE WHOLE BICYCLE

But there is more
than a frame.

Wheels, fork, lighting, racks, bags and all the little connections between them. The build only makes sense when everything works perfectly together.

So now it’s time for the final mock-up to make sure everything fits and works as planned before the frame goes off to the painter.

See the finished bicycles ↗
The pain with the paint
Polishing tool with an orange pad on a paint-marked workbench.
Freshly painted FERN bicycle frame with masking tape around the head tube.
Painter polishing the top tube of a yellow FERN bicycle frame.
Close-up of the FERN logo being polished on a yellow bicycle frame.

Photo: Stefan Hähnel

07 / PAINT

The pain with the paint

For some people, it’s just a bit of colour on the bike. For most of my clients, it’s the hardest decision of the whole build.

There are millions of colours to choose from. Luckily, we work with some of the best and most creative painters in the industry, and they’ll help you to find the right design for your bike. And in the end, your FERN becomes your very own individual masterpiece.

No bike without the bags
Tine cutting a paper pattern for a custom Gramm Tourpacking bag.
Close-up of the Gramm label sewn onto orange bag fabric.
Orange and black fabric panels, buckles and cords laid out for a custom Gramm Tourpacking bag.
Purple Gramm Tourpacking handlebar bag on the FERN Empathy Ways bicycle.
Open purple Gramm Tourpacking handlebar bag with bright pink lining on the FERN Empathy Ways bicycle.
Close-up of the pink lining, purple fabric and Gramm label on the open handlebar bag.
FERN Stripeoneur with colour-matched Gramm Tourpacking bags and panniers.

Photo: Stefan Hähnel (workshop photos)

08 / BAGS

No bike without the bags

When the frame is ready for paint, Tine from Gramm Tourpacking jumps in and makes custom bags by hand to match your bike perfectly. Together, you’ll talk through what you need to carry, and she’ll make a set of bags that works for you.

And sometimes we even get the painters involved for a bit of colour-matching craziness.

A smiling rider collecting a purple custom FERN bicycle with matching Gramm Tourpacking bags and balloons.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
Custom FERN bicycle and its details, ready for collection from the Berlin workshop.
THE BUILD IS FINISHED. THE JOURNEY BEGINS.

09 / COLLECTION DAY

Your FERN.
Ready to ride.

After all the conversations, drawings and hours at the workbench, this is the moment we’ve been working towards: you and your finished FERN, together at last.

When you collect your bicycle, we’ll go through the complete build together, check the final details and make sure you feel at home on your new bike. There’s time for questions, a first ride and, of course, a photo before you head off.

From here, the stories belong to you. I’m always happy to hear where your FERN takes you. Happy riding!

See the finished bicycles ↗