Bespoke Continuous Hinges for Bike Box
April 2023
The Task
The largest UK company specialising in hard case box rentals and sales, Bike Box, came to Cooke Brothers to customise one of their standard continuous hinges.
More about Bike Box
Bike Box is a well-known, reputable company that specialises in selling and renting out sturdy, and reliable bike boxes to professional and amateur athletes around the UK.
Bike box requested our standard continuous hinge products for customisation. Seeing as they are a high-quality manufacturer, we knew we needed to make this hinge as sturdy and reliable as possible, as well as ensure it can withstand the outdoors. In addition, Bike Box requested that we design the hinge to match their incredible, branded Bike Box case: The VeloVault.
Our plan
Our first thought was that the hinges Bike Box chose would not be the right fit for the product they wanted to use them on, so we worked out a way to correct them to the right size, without losing any of their robustness. We then decided that for extra control, we would change the type of holes our standard continuous hinges were designed with.
The last part of our plan was ensuring we had the right tools and equipment to personalise the colour of the Bike Box branded, The VeloVault.
What we did
The first thing we did was crop the hinge to the correct length needed for Bike Box’s product, with a good, clean, and professional finish.
The next step was to replace the standard countersunk holes with normal drilled holes; this was done to ensure our hinges offered the greatest contact between the fastener head and the surface of the hinge. This part of the process required some engineering in our design, but we nailed it perfectly.
And finally, since it was for the highly acclaimed British-made design, The VeloVault case, powder-coated black and RAL 5010 blue finishes were applied to ensure that it matched the other materials flawlessly.
The Results
The beautiful colours we mixed and coated the hinges in, not only provide an aesthetically pleasing result but also signal a commitment from the Cooke Brothers to their high standards of quality, and attention to detail.
Ultimately, all of these customisations resulted in a unique and functional hinge that exceeded the needs of Bike Box, and we look forward to working with them again in the future.
How Cooke Brothers can help you
If you need bespoke products to elevate your designs, we can make it happen. Product design, research and development, robotic welding, product testing, and more are all provided by us, so you can be sure we can and will deliver the product you are after.
Find out more about our bespoke products here, or contact us to speak to one of our friendly experts.
