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Rockguardz Factory Visit: Carbon Frame Protectors in the Making

Deep in the heart of the UK’s Shropshire hills nestles a small and indiscriminate works unit. Surrounded by other small units, this humble little place has no big signs on the door, the heating is barely existent and there are no corporate works uniforms in sight. But the products they produce are one-offs, we cannot think of anyone in the world producing such a wide range of layered up carbon mudguards and down tube guards; it’s time to look behind the curtain at Rockguardz.

When it comes to mudguard desirability, Rockguardz are king
When it comes to mudguard desirability, Rockguardz are king.

These guys have a really good name for themselves locally; they have now been producing their three different sized mudguards (all made in-house) and downtube protectors for around four years. They scramble around the local bike shops to take moulds for every new model of bike every year, producing guards that fit exactly to the frames. If they haven’t got the mould they offer a free guard to anyone who turns up with the first one of it’s kind bike they can take a mould off.

The moulds are key, it takes time to build up an inventory from the ever changing market.
The moulds are key, it takes time to build up an inventory from the ever changing market.
Is this a deliberate typo, or Troy's own bike?
Is this a deliberate typo, or Troy’s own bike?
Once an order comes in the correct moulds are laid out ready for production.
Once an order comes in the correct moulds are laid out ready for production.

The work that goes into these things is labour intensive, once the mould has been made and is in stock, the layering begins. The process goes from lacquering up, applying the layers, setting the soft guard, cutting the material, then eventually these things are polished up and shipped out to order all around the world.

The layers of carbon fibre are laid into the mould.
The layers of carbon fibre are laid into the mould.
Gel coat is added to cure the Carbon Fibre.
Gel coat is added to cure the Carbon Fibre.
The layered up carbon then has to go into the fridge to cure.
The layered up carbon then has to go into the fridge to cure.
The Rpckguard-edges are cleaned down ready for the fibreglass.
The edges are cleaned down ready for the fibreglass.
Carbon is mixed with fiberglass for more suppleness.
Carbon is mixed with fiberglass for more suppleness.
The fibreglass is sandwiched in next.
The fibreglass is sandwiched in next.
The edges of the Rockguard are smoothed and cleaned.
The edges are smoothed and cleaned.
Final polishing of the Rockguard by hand.
Before final polishing by hand.

The mudguards are a slightly different story, as they are a universal size and design, although the guys are always experimenting and improving, these are a one-size-fits-all affair. They have made some big improvements with the Mk2 from the Mk1. The first year we used these, we saw several breakages with the Mk1, now with the Mk2 it’s a fit and forget affair, with their structure offering tons of stiff support and strength.

Certainly not for human consumption! Gel coat.
Certainly not for human consumption! Gel coat.
Some of the chemicals used can send you to another time zone!
Some of the chemicals used can send you to another time zone!
Classic UK workplace banter!
Classic UK workplace banter!
Moulds for the upside down forks that have yet to become commonplace.
Moulds for the upside down forks that have yet to become commonplace.
The completed guards ready for shipping.
The completed guards ready for shipping.

Mudguards have traditionally never been sexy, but the Rockguardz are the first to blend functionality with style, and after a visit to the old-school unit and watching how much time and effort is put into their production, they are definitely a labor of love.

For more information visit the Rockguardz website.

Words and photos: Jim Buchanan

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