Frames are touched up by hand after exiting the automated sprayer. Er, and no, these workers weren’t wearing respiratorsJames Huang/Future Publishing
Time for paint! This setup sprays the entire frame as it passes through the chamber. The central nozzle sprays in 360° and also moves up and down. The frames flips sides as it passes around the back so everything gets coveredJames Huang/Future Publishing
Once the paint is done, it’s off for decalsJames Huang/Future Publishing
Clearcoat layers are applied by handJames Huang/Future Publishing
Upper-end frames are sent into this room to have decals appliedJames Huang/Future Publishing
The computer screen up above guides the technician on where each decal is supposed to goJames Huang/Future Publishing
The wet slide decals are carefully applied, then excess fluid is squeegeed out from beneath the vinylJames Huang/Future Publishing
If all goes well, each decal virtually disappears beneath the clearcoatJames Huang/Future Publishing
Decals soak in water before they’re applied to the framesJames Huang/Future Publishing
It takes a steady hand to apply all of these decals as intendedJames Huang/Future Publishing
Decals air dry before heading off for clearcoatingJames Huang/Future Publishing
Cheaper frames are finished in decidedly less glamorous working conditionsJames Huang/Future Publishing
Freshly decalled rear triangles waiting for final coats of clearJames Huang/Future Publishing
Minor clearcoat blems can be sanded out and resprayedJames Huang/Future Publishing
Full-suspension frames undergo further alignment checks after all of the pieces are bolted togetherJames Huang/Future Publishing
Paint and decal work can’t be done in overly hot and/or humid environments so both of those parameters are carefully controlled and monitoredJames Huang/Future Publishing
Completed frames travel on hooks to the first stage of assemblyJames Huang/Future Publishing
Build kits are organised into sub-assembliesJames Huang/Future Publishing
Giant’s factory workers actually assemble the bikes upside-down so as to not leave any clamp marks on frame tubing or dropoutsJames Huang/Future Publishing
So you think you’re fast at building wheels, eh? Check out how many spokes this technician is loading into a hub at onceJames Huang/Future Publishing
While it’s true that a machine is actually threading the nipples on to the spokes, the workers are still astonishingly quick at lacing the spokes and lining everything upJames Huang/Future Publishing
Say what you will about machine-built wheels but one thing is indisputable – these suckers are fastJames Huang/Future Publishing
Wheels are automatically tensioned and truedJames Huang/Future Publishing
A computer readout displays the actual measurements for the wheel being built. Note the timer at lower rightJames Huang/Future Publishing
Most of the assembly work is done by handJames Huang/Future Publishing
Pneumatic tools are preset to ensure proper torque specs – and to save the hands of the factory workersJames Huang/Future Publishing
Factory workers use this nifty pneumatic press to install chain rivetsJames Huang/Future Publishing