We’d like to open up the Niner archives, and give you the history of a product in the making, from start to finish; to show you how engineering, computer analysis, structural testing, riding, and passion all combined to make aluminum and steel evolve into an amazing bike. This is only one story, but it should give you a great idea as to how we approach the design and development of everything with the Niner name on it. The First Version of a Good Idea: In early 2005, we built the very first rideable samples of the W.F.O. 9 (image 1). which we showed at Interbike 2005. Our intentions were twofold. First, we used these early prototypes to help develop CVA™ suspension – the first W.F.O. 9 was 6” of travel with relatively short chainstays. Second, we wanted to encourage the component and fork makers to expand their scope of vision in regards to the 29” wheel and to develop products that would make such a bike viable. We wanted to push the limits and change the perception that the big wheel wasn’t just for single speeds. For us, the wheel size has applications across the board, but we couldn’t do it alone. We knew then the possibilities that the 29” wheel held in
<< PREVIOUS PAGE	NEXT PAGE >>

We’d like to open up the Niner archives, and give you the history of a product in the making, from start to finish; to show you how engineering, computer analysis, structural testing, riding, and passion all combined to make aluminum and steel evolve into an amazing bike. This is only one story, but it should give you a great idea as to how we approach the design and development of everything with the Niner name on it.

The First Version of a Good Idea:

In early 2005, we built the very first rideable samples of the W.F.O. 9 (image 1). which we showed at Interbike 2005. Our intentions were twofold. First, we used these early prototypes to help develop CVA™ suspension – the first W.F.O. 9 was 6” of travel with relatively short chainstays. Second, we wanted to encourage the component and fork makers to expand their scope of vision in regards to the 29” wheel and to develop products that would make such a bike viable. We wanted to push the limits and change the perception that the big wheel wasn’t just for single speeds. For us, the wheel size has applications across the board, but we couldn’t do it alone.

We knew then the possibilities that the 29” wheel held in

regard to longer travel bikes, so we decided to keep refining our frame. During 06-07 new technologies and new building methods re-adjusted our thinking, and we took roads previously untraveled.

Additionally, every Niner version-prototype goes through a battery of testing, including actual ride time (there are some perks to being bike designers). We put a lot of trail-hours in on the first versions and incorporated what we learned into the next step.

Revisions and Testing:

Interbike 2007 gave us the opportunity to share the results of these new design philosophies and technologies (image 5). W.F.O. 9 version 2 features a 1.5” head tube and 150mm spacing in the rear. Concurrent to the Interbike debut, we tested bushings vs. bearings as well as other design elements.

The long travel machine generated a lot of interest. The demand was there, our sales staff was inundated by riders eager to know the release date, but we didn’t feel like it was ready. We knew we could make something even better.

Time to ask questions: What worked and what didn’t in the first two versions? What could we do better? As Niner grows, so too does our access to new technology, both in design and construction – how could we best take advantage of?

More sophisticated computer FEA (Finite Element Analysis) provided answers to some of our questions. FEA is perfect for bicycle development, as it allows us to see in graphic form the actual stresses on a tube as force is applied. FEA enabled us to change the vector and amount of force within the FEA model and conduct computer testing on a number of structures in a day that would take months to build in actual metal. The resulting data helped us to determine the best shapes and structures for the W.F.O 9.

The testing and development process also convinced us that hydroformed tubing is the way to go - we can maximize tube shape for strength and stiffness. Additionally, forging helps us to make stronger, sexier and lighter parts. Armed with that information, as well as more hours of riding, we created the third, optimized W.F.O. 9 generation.

On this round of physical, destructive testing, we were

able to put our FEA modeling to task, to be sure that our computer generated calculations coincided with the real physical tests before opening expensive tooling for forged and extruded.

The W.F.O. 9 is the most tested bike we have ever designed. It meets all current testing standards, including those not required here in the United States. The W.F.O. 9 exceeds all testing parameters set forth by the EU’s CEN standard. This new standard is stricter than the severe testing requirements of the German DIN+ test protocol.

Excellent Industry Partners:

In the time we spent developing the W.F.O. 9, the industry began to change. A noted swing in perception, created the optimum environment for the W.F.O. 9 to spread it’s wings. Component makers stepped up to the plate to make products that better fit this style of riding. Tires appeared with wider profiles, fatter knobs, and stiffer casings.

Shimano provided valuable assistance to our project. Our two companies had many conversations regarding front derailleur improvements to resolve clearance

issues that plague big wheels and short chainstays, particularly on long travel bikes. The result is a Shimano-redesigned high mount bolt-on derailleur that we can place wherever we need to without regard for the seat tube angle or position, while still giving us critical room behind the derailleur for tire clearance (images 12, 13).

Next, we were approached by Marzocchi to help them re-enter the 29er market, as they too believe in the application of longer travel suspension designs for the 29” wheel. We put our collective heads together and wrote a list of “have to” parameters and then the Marzocchi engineers took over. We couldn’t be more pleased with the product of this collaboration – a beautiful Marzocchi 44 29er fork with 100-140mm of adjustable ATA travel, an air cartridge, 15mm quick release thru axle, compression, rebound and lockout (image 16). The W.F.O. 9 will feature a first for a 29er: a tapered head tube designed to accommodate a 1.5” lower race with a 1 1/8” upper, and the Marzocchi 44 will feature a steerer tube/crown assembly to match, making the 44 the perfect mate for the W.F.O. 9 (images 14, 15). We are honored to have worked with Marzocchi and to have played a role in bringing this fork to market. The 2010 Marzocchi 44 will be available OEM

exclusively through Niner for 2009, and available aftermarket early 2009.

The Finished Product:

With each iteration the design improved. The final production design has had countless hours of testing and refinement and embodies our design philosophy - Niner bikes must incorporate amazing ride with strong engineering and an elegance in execution. If you compare the pictures of our first design to the final version we think you will agree that the W.F.O. 9 exceeds these criteria. We hope this gives you a little better idea of the countless hours we put into the making of our frames and the many details that you might not notice right away but that are enjoyed on every ride. Our level of commitment to the Big Revolution is unmatched in the industry.

Download a complete version of this story in the downloads section below.

TESTING AND DEVELOPMENT