Video: The making of a Condor Leggero carbon frame

Here’s a nice video showing the manufacturing of Condor’s Leggero carbon frame in Veneto, Italy. This is the top-end race frame from the London bike shop, as used by the Rapha-Condor-JLT professional team.

All carbon frames are made by hand, even those from the big manufacturers, but some are a bit more involved than others. The Leggero uses the tube-to-tube method, with precisely mitred tubes bonded together. Strips of carbon are strategically wrapped around the tube junctions.  A special jig is used to assemble the various tubes into the desired geometry, before it’s all put in an oven and cured for a specific time and temperature.

The video claims each Leggero and Barachi take a day to build. Condor say the frame is made from a combination of uni-directional and directional high modulus carbon, to achieve the desired level of stiffness. All cables are naturally routed internally, it’s Di2 and EPS compatible and comes with a Deda Nero Supermacy full carbon monocoque fork

The Leggero, while it has been around for a few years, has been constantly updated in that time. They get a lot of feedback from the race time and that has helped evolve the design. As you’d expect for a race frame, there are plenty of key details to boost stiffness. A tapered head tube with 1-1/8” at the top to 1-½” at the bottom bearings up front, a BB30 bottom bracket down below and oversized tubes feature throughout.