Lynskey Performance uses a masterful combination of science, engineering, and art.  

Here's what happens after LPD receives the dealer spec sheet for your frame, which includes measurements and a description of your riding style and goals.

1. The Design phase:

A.  David evaluates and confirms that the base assumptions on the spec sheet are valid (have you chosen the right level of frame for your riding style, for example).   Once this is established, David communicates the information on the dealer spec sheet needed for a preliminary drawing of your frame to be prepared by Chris Lynskey.  This drawing will be a tool for your interview with David.  During this process you and the dealer will also be confirming the graphics scheme with LPD's graphic artist. 

B.  Your interview with David takes place. Any changes that need to be made to the design are discussed. Customer desires are confirmed.  David then finalizes both the geometric design and frame performance (tubeset design).

C.  New drawings are made based on any needed changes.  The new drawings are reviewed, and the dealer submits final approval.  Now that the design phase is over, your frame is ready for production.

2. The cold-working process for your tubing set is determined by David and carried out with LPD's state-of-the-art tools (see PezCycling News' July 24 article).  To optimize the performance characteristics of a tube, whether it is a top tube, seat tube, or down tube, or a seat or chain stay, LPD shapes it by cold-working it with some very sophisticated tools David designed and built himself.  The process is called "cold-working" because the tube isn't heated for shaping.

Due to titanium's "metal memory", a titanium alloy tube bent under normal conditions will simply return to its original shape.  Ultimately this is a very desirable characteristic, but it makes cold-working a time-consuming and labor-intensive process.  This is one of the reasons titanium frames are more expensive than most frames built with other materials.

Cold-working 6/4 titanium is even more time-consuming than cold-working 3/2.5.  This is one of the main reasons the Level 4 is Lynskey Performance's most costly frame.

3. LPD butts your tubing.  LPD uses special sanding machines designed by David to shave off weight from each 3/2.5 titanium tube in your frame.  The goal is to make your frame the lightest possible for a rider of your size and your riding style, with no compromises in  performance or durability.  This too is a time-consuming process, due to the hardness of 3/2.5 tubing. 

Since 6/4 is so hard that it doesn't lend itself to butting, the thinness of the sheet of 6/4 used to make the tube is the key factor in lightness for a Level 4.  The thinner the 6/4 sheet used to construct it, the lighter the tube will be.

4. Tube ends are cut for joining.  Yet another reason why titanium is relatively expensive:  The hardness of the metal makes it more resistant to cutting.  Cutting tools for titanium wear out and need to be replaced more often than tools used to cut steel or aluminum.  

5. David weighs each tube in your tubing set.  The goal is to come as close as possible to the desired frame weight you and David agreed on during your interview.  Since each rider is unique, the forecast frame weight is an educated guess based on prior experience, but David is seldom off by more than 70 grams.  David also weighs the material removed from a butted tube, to help ensure accuracy.

6. The jig is set up for your frame, using the life-size drawings rendered in step 1C.

7. All in the family:  Toni Lynskey welds for both strength and beauty.  Toni's torch looks more like an artist's brush than what most folks regard as a typical welding torch.  No sparks flying here:  A weld corrupted by an "active" gas like oxygen or nitrogen makes titanium brittle (and therefore breakable) in the area surrounding the weld.  An inert gas like argon or helium (see the hose attached to the bottom bracket shell) is used to purge the area around the weld of air-born contaminants.  Toni also uses white cotton gloves to avoid hand-born contaminants.

8. Your frame is checked for alignment.

As with any top frame builder, checking alignment is a key element in Lynskey's quality control.  This happens several times during the welding process, followed by a final alignment check after the frame has been completed.

9.  The bottom bracket shell is tapped (threaded).

The 6/4 ti used for all of Lynskey's bottom bracket shells needs to be tapped to accept a crank set's bottom bracket.  This requires sharp tools, lots of cutting oil, and a perfect interface between tool and material.

10. After finish, your frame is ready for shipping.

The entire process, from step 1 through step 9, takes from 3 to 8 weeks for a custom frame.  It all depends on how many people are ahead of you after your interview with David.   

Tubing sets for House Blend frames are pre-selected for each frame size and thereby require less work.  This means delivery time will be even faster if you decide not to go custom.