Boxer’s founder and chief designer Jeremy Davies riding a Rocket

The Boxer Factory

The Boxer Cycles factory lies in the heart of the industrial area of the port of Poole in Dorset. Due to the high level of local industry in the marine sector, within a mile we have access to a wealth of highly skilled labour such as aluminium fabrication and upholsterers that we use to produce our many of  our component parts. By outsourcing our part manufacturing and process work locally we can keep our costs low, but still have a firm grip on quality and lead times.We can react rapidly to market demand or quickly produce custom trike design orders.

In our factory we use traditional machines that require a great level of skill and experience to use, such as the English wheel, sheet metal roller or the shrinking machine which we use to form curved aluminium profiles for the Rocket.

We pride our selves on keeping these old skills alive whilst at the same time employing new technologies such as CNC water jet cutting and laser cutting to ensure that our frame parts are manufactured ‘clock on’.

Our assembly process is as follows and differs model by model;

  1. Frame tubes or girders are delivered with all of the interface joints laser profiled
  2. Machined parts such as bottom brackets, seat posts and front pivot bearings are CNC milled out of solid bar or tube in a neighbouring workshop
  3. These frame parts are assembled into our jig and are then TIG welded together and finished
  4. Smaller items such as cable lugs and mudguard hangers are soldered in place.
  5. For the Rocket, the front end parts are laser cut from a single sheet of aluminium – almost like a jigsaw puzzle. We then use the English Wheel, Shrinker, Rollers and Hydraulic Press to turn these flat 2D parts into our beautifully contoured finished parts.
  6. These parts are then hand riveted together using the same process that was employed to build the airliners of the 1930’s
  7. Once all the frame parts are finished they are sent to the powder coaters to be sand blasted and to receive the customers chosen colour scheme. The painted parts are then cured overnight in the ovens.
  8. Upon their return the front and rear sections are joined together using the pivot bearing assembly. And our hand built heavy duty wheels are added to create a rolling chassis.
  9. The electric propulsion system is then fitted by our electro-mechanical assembly technicians if required
  10. The rolling chassis then receives its decals and upholstery panels
  11. The cycle is then handed from the engineers to the cycle mechanic who assembles all of the cycle mechanisms such as the gears, cables, saddle and brakes – the cycle mechanic ‘sets up’ the trike and signs off on the pre delivery inspection report (PDI) – this involves a half mile ride around the block and up our nearest hill to ensure that the trike performs correctly.
  12. Our cycles are then protected and either delivered by our dedicated driver to UK addresses or part disassembled and boxed for overseas shipment by pallet freight.