Each Windcheetah is hand made and assembled by a dedicated team of craftsmen engineers. We start with some straight lengths of aluminium tubes. These are cut to length and the main tube is machined along its length to provide a precise fit for the centre casting which forms the heart of the cruciform chassis. Production tolerances for the glue system we use are typically as low as 0.003" so great care has to be taken to ensure that components are produced to this level of accuracy.

The main tube then has the two bends set into it with a hydraulic former, and all the tubes are highly polished before being sent for anodizing. The pre-polishing is time consuming but helps to achieve an outstanding finish on the tubes. Whist this work is going on the castings, or lugs, are being machined. Each Windcheetah has 14 cast lugs in its construction. These are made to our specification and design by a local foundry. They are hand made by a sandcasting process. Once we receive them they have in excess of 140 precision machining operations carried out on them. After machining the castings are hand fettled and sent out to be powder coated. We use a high specification polyester surface coat, the colour options are chosen carefully for their excellent pigment retention. A lot of our machines are used in hot climates and this resistance to colour fade is important. At this point the collection of tubes and castings is issued with its brass serial number plate. This number connects it to the relevant customer order and becomes the machines identity from this point.
Batch of Windcheetahs for the German market
Whilst these various production stages are being carried we will be making the various special components that are required for final assembly; axles, track rods, pulleys etc. All in all there are approx 60 specially made detail components in a Windcheetah.

The finished castings are then bonded to the tubes to form the chassis. Each chassis is cut to length according to the customers measurements. The bonding methods we use are a combination of thixatropic epoxy type or anaerobic systems. These give a bonded joint strength that is as strong as a weld. Curing takes up to 24 hours and the chassis is held in a jig to ensure perfect alignment during this process. All internal lug fitting is achieved by hand reaming the appropriate tube to ensure that all bonded joints are within tolerance. The brass serial number is bonded to the main tube.

The chassis is now placed into an assembly stand and built according to the customers order specification. Accessories are fitted at this stage as well as the specially built wheels. Transmissions are carefully set up and adjusted to ensure perfect gearchanging. Finally the moulded carbon fibre seat is fixed to the machine and the Windcheetah is taken on an extended test ride on the quiet country roads near to the factory… it's a tough job, but someones got to do it!

Once our final quality checks are done we remove the seat, wheels and kingpins, swathe the Windcheetah in layers of bubble wrap and pack it in the box for despatch.