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  1. #1
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    Intense Cycles Factory Forum

    I thought this would be a cool way to give some insight into the daily happenings here at the Intense factory. I'll be posting random photos from the shop as often as possible. Feel free to add requests, and let me know if there's anything you'd like to see more of! Let's keep the comments positive please! Here are a few to start-

    Intense Cycles Factory Forum-photo-1.jpgIntense Cycles Factory Forum-photo-2.jpgIntense Cycles Factory Forum-photo-5.jpg
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  2. #2
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    Kenny finishing up assembly on an Uzzi frame

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  3. #3
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    Was just able to snap this one of world-famous Rick the Welder doing what he does best, layin' dimes!

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    All that sweet goodness like colorful gumdrops so close to Christmas...Shame on you Sam!!


    BTW Thanks for those bearings... (and stickers)

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    I'm a Tig welder at Boeing, I also do the Heat Treat. Is it possible to see the Heat Treat set-up, I believe it's like the set-up here, a "drop-bottom"? I wish I could go in there and weld my own frame. I love to see pics of the shop.

  6. #6
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Was just able to snap this one of world-famous Rick the Welder doing what he does best, layin' dimes!
    I miss him posting here! But good to see he is still creating art.

  7. #7
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    Can we see some of the Asian composite side of things? Are they painted in Asia or US&A?

    Also some of the design process, r&d, prototype bikes etc

  8. #8
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    Sam, I noticed that the Uzzi frame that Kenney was finishing up has a Crane Creek DB air shock. Does intense recommend the standard air canister or the XV canister?

  9. #9
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    Quote Originally Posted by Thelma Viaduct View Post

    Also some of the design process, r&d, prototype bikes etc
    Prototype bikes? Haha you know I can't do that!
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  10. #10
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    Quote Originally Posted by dab View Post
    Sam, I noticed that the Uzzi frame that Kenney was finishing up has a Crane Creek DB air shock. Does intense recommend the standard air canister or the XV canister?
    We recommend standard can for the Uzzi, but based on personal preference on how you'd like the bike to ride you can play around with the XV can as well as volume adjust spacers.
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  11. #11
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    Fresh candy!

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  12. #12
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    Quote Originally Posted by azmxr177 View Post
    I'm a Tig welder at Boeing, I also do the Heat Treat. Is it possible to see the Heat Treat set-up, I believe it's like the set-up here, a "drop-bottom"? I wish I could go in there and weld my own frame. I love to see pics of the shop.
    Correct, industrial drop-bottom furnace. I'll try to grab a pic for ya later.

    EDIT: This is what you're looking for

    To the Point: Heat Treating Aluminum Frames - Pinkbike
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  13. #13
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    Sam - thanks so much for putting these up! I took a tour a few years ago and was definitely a great day!
    Uzzi

  14. #14
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    Gettin' JIGgy with it!



    Intense Cycles Factory Forum-frame-jigs.jpg
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  15. #15
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    This is such a cool thread, thanks for posting Sam!

  16. #16
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    More frames being born

    Intense Cycles Factory Forum-monocoque.jpg
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    Awesome pictures, makes me appreciate my 13 Uzzi even more!

  18. #18
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    More frames being born

    Click image for larger version. 

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    those welds look more like nickels
    breezy shade

  19. #19
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    Hmmmm the Intense factory in Temecula. What could possibly be missing from these photo's.......INTENSE RED WITH YELLOW GRAPHICS. The color scheme that built the name.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  20. #20
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    From raw material to aluminum art

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  21. #21
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    From raw material to aluminum art

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    Awesome! Throw some Intense red on there now.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  22. #22
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    Quote Originally Posted by DIRTJUNKIE View Post
    Awesome! Throw some Intense red on there now.
    Just for you...Kovarik's M1 Frame

    Also, watch him shred in a new edit released today: Summer of Summit: Segments - Chris Kovarik - Pinkbike

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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Just for you...Kovarik's M1 Frame

    Also, watch him shred in a new edit released today: Summer of Summit: Segments - Chris Kovarik - Pinkbike

    Click image for larger version. 

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    Kovarik is beyond rad... the man can shred like no other.

  24. #24
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    Quote Originally Posted by gretch View Post
    Kovarik is beyond rad... the man can shred like no other.
    Thank's for that I got my red fix on.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  25. #25
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    Machine Shop Monday!

    Lower links mid-production

    Intense Cycles Factory Forum-vpp-box-links.jpg
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  26. #26
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    When you see all that custom machining + hands on fabrication, makes frame prices look like a discount deal. (especially here in so. cal.)
    Thanks Sam for the pics.

  27. #27
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    When I went to the factory, I thought the same thing! I saw some expensive looking dudes walking around, more than one CnC router, and place where they dip the frames post weld into for treating..it's not some garage where they weld a few parts together. It's no joke over there. Then you walk out in the parking lot and there is Jeff testing some new design! Disney world for MTB geeks for sure.
    Uzzi

  28. #28
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    A very, very lucky person is going to be the owner of this sick ride.

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  29. #29
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    Our sales office is fueled by French Pressed Coffee and Imperial IPA's. In case anyone was wondering what to get us for Christmas.... haha!

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  30. #30
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Our sales office is fueled by French Pressed Coffee and Imperial IPA's. In case anyone was wondering what to get us for Christmas.... haha!

    Ha,ha hint,hint. Merry Christmas Sam & Jeff and all at the at tense factory.

    I can't believe I lived in San Diego for 25 years and the last 4 years I lived there I made deliveries in Temecula all around your location. And I never made it in there, now I'm back in Colorado and it's all just a memory. I drove by so many times but was alway's working and couldn't make the time. I once ran into Jeff and a large group at San Juan Trail. Seem's they were testing new rides all geared up and in Intense jerseys way back in 2002'.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  31. #31
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    One of the advantages of having an in-house machine shop is the ability to reproduce parts for bikes that are long out of production. Just because we no longer make them doesn't mean people no longer ride them or need parts! The boys in the machine shop just finished up some links for M6's

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  32. #32
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    One of the advantages of having an in-house machine shop is the ability to reproduce parts for bikes that are long out of production. Just because we no longer make them doesn't mean people no longer ride them or need parts! The boys in the machine shop just finished up some links for M6
    Awesome! How far back do you still make parts for.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  33. #33
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    Quote Originally Posted by DIRTJUNKIE View Post
    Awesome! How far back do you still make parts for.
    Depends on the demand, but we have (limited) inventory of certain replacement parts for bikes even 10-15 years old.
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  34. #34
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    Sam I'm curious what the max rim/tire combo fitment is for the Tracer 29 rear tri? I'm brainstorming a new bike that will use the new dirt wizard 2.75's on 35mm blunts.

  35. #35
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    Quote Originally Posted by nvphatty View Post
    Sam I'm curious what the max rim/tire combo fitment is for the Tracer 29 rear tri? I'm brainstorming a new bike that will use the new dirt wizard 2.75's on 35mm blunts.
    I'm not speaking for Sam, but I ran an Ardent 2.4 on the rear of my T29. It was a tight fit.

  36. #36
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    Quote Originally Posted by Captain Cobb View Post
    I'm not speaking for Sam, but I ran an Ardent 2.4 on the rear of my T29. It was a tight fit.
    that may well put the kabosh on my idea for an intense.

  37. #37
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    Quote Originally Posted by nvphatty View Post
    that may well put the kabosh on my idea for an intense.
    Nope, definitely not enough clearance there for a 2.75

    Pretty sure most 29er's out there will not be able clear that tire...
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  38. #38
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Nope, definitely not enough clearance there for a 2.75

    Pretty sure most 29er's out there will not be able clear that tire...
    heck even a 26er would do and most likely equate to a 27.5

  39. #39
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    Another edition of machine shop Monday... Rear yoke/pivot piece being born

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  40. #40
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    You guys do beautiful work Sam.

  41. #41
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    Quote Originally Posted by Captain Cobb View Post
    You guys do beautiful work Sam.
    yes indeed. Good to see the process of such trickness.

  42. #42
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    Dave doing an alignment inspection on a Tracer 275 Rear. Each frame goes through this one by one.

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  43. #43
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Dave doing an alignment inspection on a Tracer 275 Rear. Each frame goes through this one by one.

    Click image for larger version. 

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    so what tolerances are you guys OK w/ seeing go out the door for sale?
    breezy shade

  44. #44
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    Quote Originally Posted by nhodge View Post
    so what tolerances are you guys OK w/ seeing go out the door for sale?
    Not sure of the exact number, but it's very strict.
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  45. #45
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    A batch of Spider 29 Comp frames getting ready to be built up today. These things are sexy!

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  46. #46
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    I've been riding Intense frames since the previous century, it's nice to see some peeks on the inside. Keep 'em coming.

  47. #47
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    Mike Metzger stopped by today! Legend!

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  48. #48
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Mike Metzger stopped by today! Legend!

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    Very cool, is he still local to Murrieta / Temecula.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  49. #49
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    Sorry for the lack of posts! Intense HQ is under renovation and it's been madness. Anyways, here are some badass 951 EVO frames freshly out of weld. Enjoy...
    Intense Cycles Factory Forum-951-evo-frames.jpg
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  50. #50
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    Very excite!

  51. #51
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Good news for my favorite brand. Since few years ago the carbon mtb frames are the best option for a lot of mtbikers, but I prefer the aluminum frames, and Intense Cycles and his handmade frames is the reference for all mtb brands on the market. Nevertheless, I believe that it must not lose this characteristic that has defined it, in spite of the trends of the market. Intense for life!

  53. #53
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    So what's this mean Intense is going main stream and becoming one for the masses like Specialized and so forth.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  54. #54
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    Quote Originally Posted by DIRTJUNKIE View Post
    So what's this mean Intense is going main stream and becoming one for the masses like Specialized and so forth.
    Never.

    We have no intentions of ever being like specialized.
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  55. #55
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Never.

    We have no intentions of ever being like specialized.
    Thanks Sam... that made my day...

  56. #56
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Never.

    We have no intentions of ever being like specialized.
    Best. News. Ever. 👊👍

  57. #57
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    Quote Originally Posted by DIRTJUNKIE View Post
    So what's this mean Intense is going main stream and becoming one for the masses like Specialized and so forth.


    Quote Originally Posted by Sam-IntenseCustServ View Post
    Never.

    We have no intentions of ever being like specialized.
    What about the "so forth"?
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  58. #58
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    [QUOTE=DIRTJUNKIE;10955351]So what's this mean Intense is going main stream and becoming one for the masses like Specialized and so forth.[/QUO

    hahahahahaha, thats funny DJ. I'm sure Jeff and the guy at Intense would love to be making the $$$ that Specialized is making, the guys at Intense as most know are really cool and love to ride bikes. I got a little tour last week, got meet Sam and a few others. My wife keep talking about that orange 951evo you showed us, it was pretty sick.
    Once you go slack, you never go back!

  59. #59
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    [QUOTE=vice grips;10982773]
    Quote Originally Posted by DIRTJUNKIE View Post
    So what's this mean Intense is going main stream and becoming one for the masses like Specialized and so forth.[/QUO

    hahahahahaha, thats funny DJ. I'm sure Jeff and the guy at Intense would love to be making the $$$ that Specialized is making, the guys at Intense as most know are really cool and love to ride bikes. I got a little tour last week, got meet Sam and a few others. My wife keep talking about that orange 951evo you showed us, it was pretty sick.
    VG I'm just messing with Sam, I'm Intense for life as long as they keep making amazing stuff. And as far as the Intense factory I lived not too far from it for many years. And With my work I used to go right by the place [all around Temecula] but never made it in for a tour. Now I'm in Colorado and It's not looking like I'll be making an Intense tour anytime soon.
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  60. #60
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    send some carbon frame births

  61. #61
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    So to confirm, you are NOT going to sue someone who slaps the name Tracer or M9 on their coffee mug, correct?

    Quote Originally Posted by Sam-IntenseCustServ View Post
    Never.

    We have no intentions of ever being like specialized.

  62. #62
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    Quote Originally Posted by bigdog100 View Post
    send some carbon frame births
    A dyno breaking free..
    Attached Thumbnails Attached Thumbnails Intense Cycles Factory Forum-image.jpg  

    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

  63. #63
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    In our age of mass production and anonymity, where one bike differs from the rest in the selection of anodize colors, a company like Intense is a sight for sore eyes.

    BTW, it keeps amazes me how tough and maticules the paint job on my T2 is in comparison to other "boutique like" brands, which are common around here - a testament of your craftsmanship.

    Keep up the good work - we know it's not a easy job.

  64. #64
    I fix your broken ****!
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    Been seriously slacking on posts here...sorry!

    Anyways, noticed this walking through the shop today in the bike assembly area. Why buy parts trays when you have a machine shop to make custom ones?! Pretty sweet

    Intense Cycles Factory Forum-parts-tray.jpg
    Sam Wilson
    Things & Stuff Specialist
    Beer Drinker
    Intense Cycles, Inc.
    Sam@Intensecycles.com

  65. #65
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    Intense Cycles Factory Forum

    I'd buy one of them for my garage, that's so cool!!

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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Been seriously slacking on posts here...sorry!

    Anyways, noticed this walking through the shop today in the bike assembly area. Why buy parts trays when you have a machine shop to make custom ones?! Pretty sweet

    Click image for larger version. 

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    Tubeless stems? Why did my carbine come with tubes.

  67. #67
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    Quote Originally Posted by Ratt View Post
    Tubeless stems? Why did my carbine come with tubes.
    We do not ship any bikes set tubeless directly from here, it's just not practical. Your carbine wheels should convert to tubeless fairly easily though.
    Sam Wilson
    Things & Stuff Specialist
    Beer Drinker
    Intense Cycles, Inc.
    Sam@Intensecycles.com

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    While you guys are machining random stuff, how about machining a set of M9 dropouts to run 650b wheels that keeps stock geometry???
    2000 Giant DH Team
    2003 Balfa BB7
    2004 Nicolai Nuclean ST
    *break*
    2011 Intense M9
    2014 Intense C29
    2015 Intense 951evo

  69. #69
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    Quote Originally Posted by Christopher Robin View Post
    While you guys are machining random stuff, how about machining a set of M9 dropouts to run 650b wheels that keeps stock geometry???
    Are 650B wheels making their way into the DH market?
    Woed A thunk!
    Quote Originally Posted by targnik View Post
    So I shoot off all full of bravado, hit this wee booter - grabbing some air, then I land - leading into a greasy rut.

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    Sam,
    If i am pumping grease into my lower links i cannot get extra the grease to flush out of both bearings. It usually just comes out the flush side of the same bearing each time.
    Do you have any tricks or should i just tear everything down and clean things up and look for a clog.
    I have three Intenses and they all seem to have one side that the grease prefers to exit.
    I am assuming that it would be best if the grease came out of both sides flushing out the debris / water etc.
    Any help would be appreciated as always

    Intense rules!

  71. #71
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    Quote Originally Posted by julesverne View Post
    Sam,
    If i am pumping grease into my lower links i cannot get extra the grease to flush out of both bearings. It usually just comes out the flush side of the same bearing each time.
    Do you have any tricks or should i just tear everything down and clean things up and look for a clog.
    I have three Intenses and they all seem to have one side that the grease prefers to exit.
    I am assuming that it would be best if the grease came out of both sides flushing out the debris / water etc.
    Any help would be appreciated as always

    Intense rules!
    I'd say remove the bolts and link and clean the inside of the pivot as well as the zerk fitting itself. This should get rid of a clog somewhere. Not too big of an issue either way. As long as you're getting some grease to purge out then it's doing what it's supposed to!
    Sam Wilson
    Things & Stuff Specialist
    Beer Drinker
    Intense Cycles, Inc.
    Sam@Intensecycles.com

  72. #72
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    Quote Originally Posted by Sam-IntenseCustServ View Post
    Been seriously slacking on posts here...sorry!

    Anyways, noticed this walking through the shop today in the bike assembly area. Why buy parts trays when you have a machine shop to make custom ones?! Pretty sweet

    Click image for larger version. 

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    Hay Sam, why don't you take a picture of the bike, that has that enve wheel on it
    Once you go slack, you never go back!

  73. #73
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    The Uzzi carbon one?...

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    Quote Originally Posted by vice grips View Post
    Hay Sam, why don't you take a picture of the bike, that has that enve wheel on it
    I am pretty sure I have seen that picture... it is sweet.

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    Quote Originally Posted by gretch View Post
    I am pretty sure I have seen that picture... it is sweet.
    Haha sure, I'll post the picture here on March 17th!
    Sam Wilson
    Things & Stuff Specialist
    Beer Drinker
    Intense Cycles, Inc.
    Sam@Intensecycles.com

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    I recently got a 2011 Intense M9. I was planning on putting some grease into the lower link so I tried to take the plug off with an 8mm wrench to see what grease fitting to use. The plug under the shock is difficult to take off due to the high tig weld and I rounded the hex. now it is stuck. you can see here.
    http://i853.photobucket.com/albums/a...ps64bc18cc.jpg
    The plug at the swing arm is easier to remove.
    http://i853.photobucket.com/albums/a...ps5e76ec2a.jpg
    The outside diameter of the thread of the plug is 6mm. Can someone tell me what zerk grease fitting I should get? is it a metric M6 or some SAE size? I tried putting an M6 allen bolt which i got from a seatclamp into the grease port and the fit is somewhat shaky even if the outside diameter of the thread of the allen bolt is also 6mm.

    Where can I get another grease port plug for the M9? It is not available at the Intense store? After I get a bike mechanic to remove and lube the pivots, maybe I will just put some electrical tape to cover the grease port

    After a few rides, I noticed the bike is creating squeaky noise like metal to metal rubbing. Could it be from the flip clip? Should I put grease or anti seize?

    I visited the Intense store and I see the M9 lower link has a different pivot bolt to my 2011 M9. Will this new M9 lower link kit with the new pivot bolts and possibly different bearings fit my old 2011 M9?

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    Quote Originally Posted by bendik.ph View Post
    I recently got a 2011 Intense M9. I was planning on putting some grease into the lower link so I tried to take the plug off with an 8mm wrench to see what grease fitting to use. The plug under the shock is difficult to take off due to the high tig weld and I rounded the hex. now it is stuck. you can see here.
    http://i853.photobucket.com/albums/a...ps64bc18cc.jpg
    The plug at the swing arm is easier to remove.
    http://i853.photobucket.com/albums/a...ps5e76ec2a.jpg
    The outside diameter of the thread of the plug is 6mm. Can someone tell me what zerk grease fitting I should get? is it a metric M6 or some SAE size? I tried putting an M6 allen bolt which i got from a seatclamp into the grease port and the fit is somewhat shaky even if the outside diameter of the thread of the allen bolt is also 6mm.

    Where can I get another grease port plug for the M9? It is not available at the Intense store? After I get a bike mechanic to remove and lube the pivots, maybe I will just put some electrical tape to cover the grease port

    After a few rides, I noticed the bike is creating squeaky noise like metal to metal rubbing. Could it be from the flip clip? Should I put grease or anti seize?

    I visited the Intense store and I see the M9 lower link has a different pivot bolt to my 2011 M9. Will this new M9 lower link kit with the new pivot bolts and possibly different bearings fit my old 2011 M9?
    You can get the zerk fittings from Intense (email sam@intensecycles.com), or a shop that carries Intense should be able to order them in. As for the creaking, it is the flip chips 99% of the time. First thing I would do is upgrade your existing lower link to the newer style link with the collet axles. Start with fresh flip chips and a new lower link and install with anti-seize and this will minimize the creaking.

  78. #78
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    Quote Originally Posted by bendik.ph View Post
    I recently got a 2011 Intense M9. I was planning on putting some grease into the lower link so I tried to take the plug off with an 8mm wrench to see what grease fitting to use. The plug under the shock is difficult to take off due to the high tig weld and I rounded the hex. now it is stuck. you can see here.
    http://i853.photobucket.com/albums/a...ps64bc18cc.jpg

    The plug at the swing arm is easier to remove.
    http://i853.photobucket.com/albums/a...ps5e76ec2a.jpg
    The outside diameter of the thread of the plug is 6mm. Can someone tell me what zerk grease fitting I should get? is it a metric M6 or some SAE size? I tried putting an M6 allen bolt which i got from a seatclamp into the grease port and the fit is somewhat shaky even if the outside diameter of the thread of the allen bolt is also 6mm.

    Where can I get another grease port plug for the M9? It is not available at the Intense store? After I get a bike mechanic to remove and lube the pivots, maybe I will just put some electrical tape to cover the grease port

    After a few rides, I noticed the bike is creating squeaky noise like metal to metal rubbing. Could it be from the flip clip? Should I put grease or anti seize?

    I visited the Intense store and I see the M9 lower link has a different pivot bolt to my 2011 M9. Will this new M9 lower link kit with the new pivot bolts and possibly different bearings fit my old 2011 M9?


    Also-

    You don't need to remove those fittings to add grease. Get a grease gun with a needle tip.

  79. #79
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    Thank you gretch and mbell. Sam already emailed. I will look for the grease gun with a needle tip

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    where can i buy a grease gun with a needle tip that will allow lubrication of m9 without having to remove the rear shock. i already have a grease gun. a needle tip that will fit a standard grease coupler or a needle tip that will fit a 1/8" male NPT grease gun hose will do. has someone tried this turner grease gun kit with a 45 degree bended needle tip? will this work?
    Grease Gun Kit - Turner Bikes

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    Are you getting SL carbon shock links in? Asked a while ago with no answer. Ta

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    Sam,
    I am setting up a T275 carbon bike with the XTR m980 3 x 10 crank.
    The bottom bracket shell width is 92.42 mm/just measuring the frame width
    When I install the Pressfit bottom bracket and install the crank the spindle shaft does not protrude into the into the crank arm far enough to
    have good purchase
    I can barely get a few threads to grab when i screw in the cap to tighten on the crank arm
    I tightened it up as much as possible but I am beginning to have
    problems with the crank arms working loose
    Does that bottom bracket shell width sound correct?
    I am sure that i have the bottom bracket pressed in all the way.
    any comments would be appreciated..

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