Insight: Deluxe PAModel

Photo: Brian Yeagle

A few months back, we caught up with Mark Potoczny to talk about how things were going with Deluxe and to talk a little bit about what he had in the works with his signature frame. One thing that I think a lot of people don’t know about BMX products, especially signature products, is the steps and how long it can take to get something from the idea to final production model. There’s a lot of options and angles to consider when designing a frame and Mark has been finding that out the last few months. I figured we could catch up with Mark Potoczny and Mark Noble (owned of Deluxe) to talk about how the process is coming along and find out what they have decided on for the production model. I’ve also got some sneak peek photos of Mark’s signature frame along with a few real rad riding photos courtesy of Brian Yeagle! Let’s take a look…

Note: MP – Mark Potoczny
MN – Mark Noble

All right, for this Insight, we decided to talk about Mark Potoczny’s new signature frame. Last time I heard you guys were tossing around names, have you decided on anything, or is it still the Pototype or PAModel?
MP: I still haven’t made my mind up on that one yet. Indecision is killing me on that topic!

When was the original idea brought up to have a signature frame?
MP: The idea was brought up right away. It was one of the main reasons for making the move to Deluxe. Mark offered me the chance to design a frame and I thought it was an amazing opportunity. I had always been excited about an all trails brand and that was the kick.

Was it something you wanted to do as soon as he joined the team?
MN: Oh yeah, we wanted to grow Deluxe a little, and signature frames were the way forward for sure – it made perfect sense to have Mark work on this one, and the end result is perfect. I’m stoked on how his frame has come out.

How long did it take to work out some of the original plans for the frame? Did you start from scratch, or was it more putting your own geometry on an existing frame?
MP: I really liked the geometry of the original Tech2 frame so much that my signature frame is almost a revision of the Tech2. So we stuck with the original geometry and changed a few features. I just wanted to add a gusset in the front end to make it a bit stronger. We went with a 21.5” toptube as well, which will give some extra room up front for all the tall guys out there. The rear bridges are curved which and there is a built in seat clamp. There is also a new machined bottom bracket that is new for Deluxe that compliments the machined head tube really well.

Once the ideas were flowing, how long did it take to get it all drawn up into CAD and then have a prototype welded up?
MP: The process moved along pretty fast. I was over in England last June and met up with Mark to discuss the frame. Shortly after I was home, Mark sent me the CAD drawings, and by September the first prototype arrived at my house.

You’ve worked with a few different samples, right? What were some of the changes made from the original idea to the final production model?
MP: The first prototype came in and everything felt really good. It just had a gusset on it that was WAY too big. It looked like it reached halfway to the bottom bracket. So that was the first thing to be revised. And the first frame had a 13.75” rear end with a 21.5” top tube. The production models will have a 14” inch rear end.

MN: For sure – we’ll have 14” back ends on the 21.5” XXL model, and for the XL 21” and the L size 20.75”, they will both have 13.75” back ends to keep them in proportion.

Have you guys run into any major issues with the samples? How about with Max’s frame?
MP: Nothing is perfect first go. As I said before, the gusset got a serious trim from the first prototype.
MN: For sure. Max wanted to change a few details on his frame, like geometry and lengths, he wanted his bike to feel quicker – so we made that happen.

It seems like every brand has their own twist on a heat-treating process and type of metal they are using these days. What kind of materials and heat-treating process are you guys going with for Mark’s frame? Is this what you use on all of the Deluxe frames?
MN: We always build with Japanese 4130 cromoly tubing throughout, seamless tube, and butted in the right places of course – we work closely with the frame builders to make sure it’s all good and quality is as high as possible, but at the same time keep them affordable so you don’t have to sell a kidney to get one. Heat-treatment wise, we heat-treat the headtube, bottom bracket, and the dropouts. No corners are cut here.

Care to take us through the geometry of the frame? Are you guys sticking with a 74-degree head tube angle like the other Deluxe frames?
MP: Yeah, the 74 headtube angle is here to stay for this frame. When I first joined the team, I was a bit unsure of it because I hadn’t run a 74-degree frame since my racing days. But after a week on the frame I was hooked. The thing feels like a limousine on trails. It is just so stable on big jumps, I had to stick with it.
MN: Both Mark and Max Bimar – who’s also working on a signature Deluxe frame for us – had carte-blanche to do what they wanted with their frames – if they came back to me and asked for 89º head angles, triple toptubes and a coaster brake anchor, I’d think they were a little strange but still, if it’s what they want… haha. 74 just feels so rad, so stable, so fast – like Mark says, it’s so stable on big jumps. It’s also the same as Taj’s T1. Max is going with a steeper head angle, so for riders who want a 74.5 degree headtube, we’ve got you covered too.

What are some of the other features of the frame?
MP: One feature that I didn’t mention in the previous questions is the new ovalized lower down tube. It is a really nice touch.

How close to production are you with the frame? When can we expect this to be out? Any estimated cost?
MN: We’ve got a couple small details to iron out and then we go to production on both frames right away, and so they’ll be out October this year. We take our time making sure everything’s dialed in with our products and so lead-times often seem in biblical proportions, but it’s definitely worth it to get it right. Both these frames are going to be bang on. Cost wise, it’ll be the same price as our Tech2 frame now, the chrome ones may cost a little bit more.

Do you have the final production weights, sizes and colors figured out?
MN: Sure – weight wise we are looking at between 4.7 and 4.8lb depending on frame size. Colours, we’ll be going with black, clearcoat, and chrome plate – keeping it really simple on this first batch. Graphics will be superb too. Size wise, we’ll have the 21.5” XXL model that Mark rides, plus 21” and a 20.75”. Three of the guys on our team ride 20.75” models.

What kind of a warranty does Deluxe offer for the frame?
MN: Check our website for the full details there, or on the warranty card that comes with the frame. Either way, if there are any issues – and to be totally honest there very rarely are any – we’ll take care of any issues for ya.

Do you have any other Mark Potoczny signature goods coming through with this? Bars, forks, pedals?
MP: For now it’s just the frame. I’m always open to new ideas, so we will see what is in store for 2012.

What else do you have cooking with Deluxe these days? Don’t you have another signature frame and some other goodies in the works? Can you give us some hints at what’s coming for the late 2011 / 2012 line?
MP: Right now a team trip is in the works. We will all be meeting up in France later in the summer to ride some of the amazing trails over there. I can’t wait to get over there.
MN: Good times. Along with the trip, we should be able to film plenty of that for the next video. Product wise, new stuff coming out will be the two signature frames we’re talking about here, and then refinements of our current product line – I don’t really want to expand into one of these brands that try and make anything and everything. We just want to make what we have now, only better. For 2012 we do have two complete bikes that are so good straight out of the box – those will be coming out in September, and I’m really stoked on those. They took a long time to get right, but they’re great.

Is there anything I missed you want to add?
MP: I’d just like to thank Mark and everyone at Deluxe for giving me the chance to design a frame. It is definitely a dream to get to design your own bike.

For more information about Deluxe. Hit DeluxeBMX.com.