What does it truly take to forge a path in the competitive world of bike manufacturing, to step away from a stable career and immerse yourself in the challenging yet rewarding process of creating bikes? This is the question that lingered as we sat down with Noel Buckley, the founder of Knolly Bikes, a brand synonymous with quality, performance, and a fiercely loyal customer base. From his early days as a skilled North Shore rider outside the industry, Noel has steered Knolly Bikes into a respected name, celebrated for its engineering-driven approach and unwavering commitment to the rider experience.
Knolly Bikes stands at an exciting juncture. Years of dedicated development have culminated in a revamped bike line, poised to elevate performance while streamlining production. The brand’s foray into carbon fiber in 2016 marked a significant expansion, attracting a new segment of riders to experience the unique Knolly ride. To delve into the heart of Knolly Bikes, we engaged in a candid conversation with Noel, accompanied by a selection of fine single malt whiskies – a fitting backdrop for uncovering the story behind these meticulously crafted machines. Join us as we explore the journey of Knolly Bikes, a brand built on passion, engineering expertise, and an enduring love for mountain biking.
From Physics to Frames: The Genesis of Knolly Bikes
Before embarking on his journey with Knolly Bikes, Noel Buckley’s world was deeply rooted in the precision of physics and engineering. A Physics graduate from the University of British Columbia (UBC), Noel spent a decade honing his skills as an engineering physicist. This followed a hands-on period as a machinist during his university years, experiences that would lay a crucial foundation for his future endeavors in bike manufacturing. His initial professional role was with a machine vision company specializing in advanced laser scanning systems for industrial applications, primarily in the forestry sector. This position provided invaluable insights into creating highly sophisticated products designed for unwavering reliability and accuracy in extremely demanding environments. It was, as Noel describes, an immersive introduction into rigorous Research & Development, encompassing patent work and the intricate processes of bringing cutting-edge technology to life. Later, Noel transitioned into the field of hydrogen hybrid power systems, focusing on applications engineering. Although seemingly distant from the mountain bike industry, these experiences instilled core philosophies regarding environmental understanding and stringent manufacturing requirements – principles that are intrinsically woven into the fabric of Knolly Bikes.
Knolly Bikes officially took shape in late 2006, launching its 2007 model lineup featuring three distinct bikes. However, the brand’s origins trace back to 2004 with the initial V-Tach frames, born from a more informal passion project. During this nascent phase, while still committed to his engineering career, Noel dedicated his spare time to building bikes for friends. “Honestly, it was hugely exciting!” Noel recalls, reflecting on those early days. “Everything was new, there was no being jaded about the industry, and absolutely no stress of running an ongoing business.” This pure enthusiasm and a drive to create would eventually evolve into the established and respected brand that Knolly Bikes is today.
Noel Buckley navigating technical terrain on a Knolly bike on the North Shore.
The Knolly Difference: Innovation and Fourby4 Suspension
The spark that ignited Knolly Bikes wasn’t a calculated business decision, but rather a confluence of circumstances and a deep-seated desire to innovate within the mountain bike realm. In the early 2000s, a serious arm injury sidelined Noel, necessitating three surgeries over several years. This period of recovery unexpectedly provided him with ample time to delve into bike design, a long-held fascination. As timing would have it, his extensive engineering and manufacturing background converged with the burgeoning riding scene on the North Shore and in Whistler. The evolution of riding styles and trail demands fueled his curiosity to explore uncharted design territories.
His initial project, the original V-Tach, became a labor of passion spanning a couple of years. It was during this process that Noel recognized the uniqueness and patentability of his design. He proceeded to build additional prototypes, which were rigorously tested by friends who, impressed by their performance, placed orders. This organic demand marked the unofficial inception of Knolly Bikes. It wasn’t until late 2006 that the venture transitioned into a formalized business structure, solidifying Knolly Bikes as a serious and enduring entity.
Noel felt a significant gap in the market at the time. He perceived many bikes as “pretty rudimentary,” particularly given his decade of experience in engineering and manufacturing products designed for extreme conditions far surpassing the demands of mountain biking. This perspective fueled his drive to bring a higher level of engineering rigor and product sophistication to the bike industry.
Central to Knolly’s identity is the Fourby4 suspension system. This technology, born from Noel’s engineering insights, has become a defining feature of Knolly bikes and a key differentiator in the market. As Noel explains, “The development of Fourby4 has started to take on a life of its own. The more bikes I design, the more versatile I discover this technology is.” He elaborates on the fundamental suspension designs, stating that from a motion analysis standpoint, most full suspension bikes fall into two categories: single pivot or four-bar linkage. Fourby4 represents an advanced evolution of the four-bar linkage system. Its defining characteristic is a secondary four-bar linkage, meticulously engineered to isolate the suspension system from drivetrain forces. This isolation ensures that the suspension performs precisely as intended, uncompromised by pedaling inputs or braking forces.
The versatility of the Fourby4 system is a cornerstone of Knolly’s product offering. However, this advanced design comes with increased complexity in both design and manufacturing, leading to higher production costs. Interestingly, despite its intricate nature, Fourby4 doesn’t compromise reliability or add unnecessary weight. Instead, by optimizing and minimizing forces throughout the linkage design, it achieves exceptional durability without the bulk often associated with robust suspension systems.
Single malt whisky bottles, symbolizing the insightful conversation about Knolly Bikes.
Material Matters: Aluminum vs. Carbon Fiber in Knolly Bikes
Knolly Bikes initially built its reputation on aluminum frames, a material Noel was intimately familiar with due to his extensive engineering background. When the brand was in its infancy, carbon fiber was not a viable option. Limited resources and the high cost of tooling, coupled with the less mature state of carbon manufacturing processes a decade ago, made aluminum the practical and logical choice. Furthermore, Knolly had established strong manufacturing partnerships in North America for aluminum fabrication. However, vendor challenges, a situation echoed by many competitors who subsequently shifted production to Asia, eventually led Knolly to reassess its manufacturing strategy.
Noel maintains a material-agnostic perspective, asserting that “I’m a material agnostic in terms of, in terms of what’s better.” He believes that both aluminum and carbon fiber, along with steel and titanium, can be used to create exceptional bikes. However, he acknowledges the market’s perception of carbon fiber as a superior material, often associated with high-performance applications like fighter jets and aircraft. While recognizing carbon fiber’s remarkable properties, Noel emphasizes that its effectiveness is highly dependent on application, integration, process control, and manufacturing technique. He contends that the choice between materials is less about inherent superiority and more about matching the material’s characteristics to the specific design goals and performance requirements of a particular bike.
From a rider’s perspective, the key material benefits typically revolve around stiffness and weight. Carbon fiber boasts a density significantly lower than aluminum (1.7 grams per cubic centimeter versus 2.7), resulting in a material that is approximately 35-40% lighter. This lower density allows for the construction of larger diameter tubes, enhancing stiffness. Another crucial difference lies in material properties: metals like aluminum are isotropic, meaning their crystalline structure and strength are uniform in all directions. Carbon fiber, in contrast, is anisotropic, exhibiting exceptional strength in one direction but limited strength in others. While weaving carbon fibers can partially mitigate this anisotropy, it can be less efficient in certain applications, leading to the increasing use of unidirectional carbon in bike frames.
Theoretically, manipulating the carbon ply structure offers designers the ability to fine-tune the ride feel. However, Noel argues that in the context of mountain bikes, with their inherent complexities of rear shocks, forks, suspension systems, and compliant tires, the subtle nuances of frame material feel become less pronounced compared to road bikes. In road bikes, where stiffness and direct power transfer are paramount, the material characteristics have a more discernible impact.
For riders transitioning from an aluminum to a carbon Knolly bike, the most noticeable difference is often increased stiffness, particularly lateral and torsional stiffness in the bottom bracket area. This translates to enhanced pedaling efficiency and a more direct feel. Carbon frames also tend to exhibit a slightly more damped feel, especially in high-frequency vibrations. While carbon frames can be lighter, Noel points out that the weight difference in a complete 30-pound bike build might be less perceptible to the average rider.
Knolly recognizes that aluminum frames often excel in compliance, offering a more forgiving ride feel. Noel draws an analogy to skis, comparing cap construction skis (stiff and edge-focused) to laminate ply skis (more compliant and forgiving). Similarly, a carbon Knolly Warden with stiff carbon wheels delivers a highly responsive and engaging ride, demanding rider input. Conversely, an aluminum Warden paired with a more compliant wheelset can achieve a similar level of ride compliance. The most compliant setup would be an aluminum frame with compliant wheels, offering a more forgiving and comfortable ride. Ultimately, while carbon fiber carries a certain allure and “sexiness,” as Noel puts it, there remains a dedicated segment of riders who appreciate the distinct ride characteristics and durability of aluminum frames.
A carbon fiber Knolly Warden frame, highlighting Knolly’s entry into carbon bike manufacturing.
Crafting Carbon: The Warden Carbon and Manufacturing Philosophy
The development of the Warden Carbon was an iterative process, building upon Knolly’s established engineering principles and design philosophy. Rather than a radical departure, it was an evolution, incorporating carbon fiber into the brand’s existing framework of performance and durability. When Knolly started, weight wasn’t a primary focus; bikes like the V-Tach were built for robustness. However, by the time the Warden Carbon project commenced, alongside aluminum models like the Warden Aluminum and Endorphin Aluminum, Knolly had achieved competitive weights, often below the average in their respective categories. This focus shifted the design priorities for the Warden Carbon.
“So we looked at the Warden carbon and said the first thing we don’t need to be worried about is weight,” Noel explains. “So we didn’t build this bike to be lighter. We’re happy being mid pack in the weight range. We wanted to be high strength to weight ratio, mid pack, weight wise, we’re not a super weight weenie company.” The aesthetic was also a crucial consideration. The Warden Carbon needed to be unmistakably a Knolly, retaining the brand’s visual identity and incorporating the signature Fourby4 linkage. Geometry and kinematics were largely established, with a minor 5mm travel increase being more of a marketing nuance than a significant performance alteration.
Reliability emerged as the paramount objective for the Warden Carbon. This focus dictated the choice of manufacturing process: internal mandrel molding. This more complex and less common method, while demanding greater precision and tighter tolerances, ensures superior structural integrity and consistency. Unlike bladder molding, which uses inflatable bladders to shape the carbon inside a mold, mandrel molding employs a rigid, pre-shaped mandrel. Carbon plies are laid up around this mandrel, creating the exact desired internal cavity of the frame. The challenge lies in removing the mandrel post-molding, a closely guarded trade secret among manufacturers using this technique. The mandrel process yields a more precise ply lay-up and ensures optimal fiber compaction, minimizing voids and imperfections.
“Reliability. That was actually a driving standpoint in this product, so that dictated a certain type of manufacturing process, which is the internal mandrel process,” Noel states. While not exclusive to Knolly, the mandrel process is used by a small percentage of carbon frame manufacturers due to its complexity. This process, however, aligns perfectly with Knolly’s commitment to producing high-quality, durable frames.
The meticulousness of the mandrel process allows Knolly to produce frames with a raw carbon finish, foregoing paint. Most carbon frames are painted to conceal imperfections like air pockets and pinholes inherent in less precise manufacturing methods. Stripping paint from many carbon frames often reveals fillers and imperfections. Knolly’s philosophy centers on manufacturing excellence, striving for the best possible product quality. While mandrel processes are more prevalent in critical areas like head tube, downtube, and bottom bracket junctions, Knolly applies it to the entire frame.
Despite the advantages, carbon fiber manufacturing presents challenges, particularly regarding cost. The high-end mountain bike market, as Noel points out, is not primarily driven by $10,000 bikes but rather by the $3,500 to $5,000 range (Canadian dollars). Carbon manufacturing, with its labor-intensive processes, inherently carries higher costs.
Knolly’s approach to factory partnerships emphasizes trust and collaboration. While acknowledging the industry trend of brands claiming proprietary carbon blends and manufacturing techniques, Noel is candid: “And I’ll be the first person to say that’s bullshit. And the reason is because none of these brands are building their own product.” Instead, Knolly focuses on close collaboration with its factory partner, emphasizing process control to ensure the desired product quality. While exceptions exist, such as boutique manufacturers hand-building frames in locations like California, Noel argues that for mainstream mountain bike production, relying on specialized factories, particularly in Taiwan, often yields superior results due to their expertise and advanced manufacturing capabilities. He cautions against the allure of lower costs in regions with less stringent quality control, emphasizing that quality manufacturing, even in Asia, comes at a premium.
Rider cornering aggressively on a Knolly Warden Carbon bike, showcasing its stiffness and handling.
Environmental Responsibility and Manufacturing Choices
The conversation with Noel Buckley naturally progressed to the environmental considerations surrounding bike manufacturing, particularly carbon fiber. He acknowledges the “dirty little secret” of carbon production, while also contextualizing it within the broader environmental impact of material production. He points out that aluminum smelting, for instance, relies heavily on hydroelectric power, often necessitating large-scale dam projects with significant ecological consequences. While aluminum is largely recyclable, Noel questions the actual recycling rates in practice, noting that efficient recycling systems like Vancouver’s are exceptions globally.
Knolly’s primary environmental strategy centers on product longevity. “So our first point of view goes right back to the policy we talked about maybe 20 minutes ago, which is reliability and the one thing I can control is making sure that I reduce the amount of my frames that end up in the landfill because they are broken,” Noel emphasizes. This commitment to durability is a core tenet of Knolly’s manufacturing philosophy and a key justification for employing the more robust mandrel carbon process. While carbon fiber is often marketed as having infinite fatigue life, Noel clarifies that impact damage, rather than fatigue, is the primary cause of failure in carbon frames.
He uses the example of riding in rocky terrains like Moab or Fruita, where sharp rocks can inflict significant damage to frames, regardless of material. Therefore, enhancing reliability through manufacturing processes becomes paramount in extending the lifespan of a frame and reducing waste. While Noel candidly admits that Knolly isn’t heavily involved in enforcing environmental standards at the factory level currently, he expresses a desire to exert more influence as the company grows.
He acknowledges the environmental impact of both carbon and aluminum production. Aluminum frame finishing processes, such as anodizing, involve harsh chemicals. Even seemingly benign processes like Scotch-Brite finishing of raw aluminum frames generate aluminum dust and abrasive particles, requiring proper filtration and waste management. Noel poses the question of how far down the “rabbit hole” of environmental management a company can realistically go. For Knolly, a key focus remains on maximizing the usable life of its products. While the fate of mandrels and bladders used in carbon manufacturing is a concern, with much of it likely ending up as waste, Knolly hopes to see advancements in recycling these materials in the future. However, for a company of Knolly’s size, exerting significant pressure on vendors to adopt comprehensive environmental standards remains a challenge.
Knolly Warden bike on a technical descent, emphasizing durability and performance in challenging conditions.
The Future is Fugitive: Knolly’s New Trail Bike
Looking ahead, Noel unveiled Knolly’s latest creation: the Fugitive, a versatile trail bike poised to further solidify Knolly’s position in the market. The Fugitive is offered in two travel configurations and will be initially released in aluminum, with a carbon version following within six to eight months. The primary model is a 120mm travel trail bike, designed to be highly capable across a spectrum of riding styles. Knolly bikes are known for their balanced geometry, and the Fugitive continues this tradition, leaning slightly towards the lower and slacker end of the spectrum without being extreme. The recommended fork travel is 140mm, resulting in a 66.5-degree head angle. The Fugitive also features dual geometry adjustability, allowing riders to further slacken the head angle to 65.5 degrees for more aggressive terrain. Riders seeking a more XC-oriented setup can opt for a 130mm fork and faster-rolling tires.
Noel emphasizes the Fugitive’s versatility: “This is a bike that you can go climb 5,000 feet on, it’s bike you can race EWS on, you can ride the trails in the Shore. You can take it to Moab, Sedona or Pisgah and have a great time riding.” It is Knolly’s most pedal-efficient and agile bike due to its shorter travel, yet it retains the brand’s renowned descending prowess. A long-travel version, the Fugitive LT, offers 135mm of rear travel and is designed for a 150mm fork. Remarkably, both versions utilize the same frame, differentiated by shock stroke length. The Fugitive employs a metric trunnion shock mount with a 185mm eye-to-eye length, accommodating both shorter and longer stroke shocks within the same frame design. The shorter travel version uses a 50mm stroke shock, while the longer travel LT utilizes a 55mm stroke, maintaining consistent geometry across both models.
Anticipated build weights for the Fugitive range from a very light 26-27 pounds for high-end builds to around 29-30 pounds for more typical configurations with pedals. Carbon builds will naturally be slightly lighter. However, Noel acknowledges that final weights are heavily influenced by component choices, particularly tires and the extent of carbon components used.
Noel Buckley riding a Knolly Fugitive LT on a technical trail, demonstrating its capability.
The Knolly Community: Loyalty Beyond the Bike
Knolly Bikes has cultivated an exceptionally loyal customer base, a testament to the brand’s commitment to quality and rider satisfaction. Noel attributes this loyalty to several factors: a deliberate approach to product development, prioritizing thoroughness over rushed releases; the exceptional feel and performance of the Fourby4 suspension system; the high manufacturing quality of Knolly frames; the longevity of Knolly designs, remaining competitive for years; and a strong focus on customer support.
Noel contrasts Knolly’s approach with the industry trend towards consumer-direct sales and discounting, which he views as potentially undermining customer service and product value. “I feel that certain players in our industry are in a race to the bottom, with discounted consumer direct sales. This is ultimately a parasitic business model that relies on a network of dealers for customer service but promotes a system that doesn’t support it,” he states. Knolly’s philosophy is to maintain the premium value of its products and the rider experience, resisting the pressure to devalue its offerings. Noel believes that the inherent trust customers place in Knolly’s product design, manufacturing, and the overall brand ethos is the primary driver of this remarkable loyalty.
Noel Buckley smiling while working on a Knolly bike, reflecting his passion and dedication.
Looking Ahead: The Enduring Spirit of Knolly Bikes
Reflecting on the decade-long journey of Knolly Bikes, Noel expresses a sense of both accomplishment and ongoing ambition. He acknowledges the inherent stresses and significant rewards of building a business, viewing Knolly as a living entity with its own trajectory. “I honestly feel that we’re just getting started, but I know I’ve said this 3 or 4 years ago! Maybe that’s how it always is,” Noel muses. Knolly remains a boutique company, driven by a passion for building the bikes they believe in, rather than chasing market trends or homogenization. Noel values Knolly’s niche identity, preferring to define and own their space in the industry rather than attempting to cater to every segment.
He expresses concern about the increasing homogenization of mountain bike design, where visual appeal and perceived marketability can overshadow ride quality and overall rider experience. Knolly’s commitment remains firmly rooted in delivering exceptional ride quality and a holistic ownership experience. Looking towards the future, Noel hopes to maintain this passion and drive, ensuring that the journey of Knolly Bikes remains perpetually engaging and innovative.
Small, independent builders like Knolly Bikes inject vital character and innovation into the mountain biking world. Their dedication to quality, performance, and rider experience enriches the sport and provides riders with truly unique and exceptional machines. Knolly Bikes stands as a testament to the power of passion, engineering excellence, and an unwavering focus on the rider, adding a distinct and much-needed spice to the world of mountain cycling.
