John Cutter and the Art of the Utility Bicycle

John Cutter and I go "way back," back to the early 90s, just after I stopped working at Moots Cycles.  John was building custom frames in San Luis Obispo, California, where I had just started engineering school.  While I look back on my framebuilding days with a great deal of nostalgia, John took a different route.  He never stopped building bicycles.  What's more, his designs have become increasingly interesting as his experience grows, culminating in the "Honorable Mention" he received at the 2011 Oregon Manifest Constructor's Design Challenge.  The "utility bike" (and do not make the mistake of calling it a cargo bike, as I did) he built for that competition stands out as a rolling testament to the fact that an exceptional design can make a bike practical, useful, and a joy to ride.

When I saw photo's of John's Manifest bicycle, I knew I had to interview him about it.  He was kind enough to answer a few questions for me.

John Cutter

John Cutter's Introductory Statement:  First off, I would want to touch on the term "cargo". At the Oregon Manifest there were numerous entries that I would term as being cargo bicycles, yet the contest guidelines called for a "utility bicycle". What is a utility bicycle? My design was driven by the fifty mile trials ride that we were required to complete. So for me in this case the "utility bicycle" was not going to be a cargo bicycle. It needed to be light and efficient as well as have the capacity to carry a load. So I went with the proven touring concept of distributing the weight and bulk of caring cargo between the front and rear of the bicycle. I also saw the need to be able to handle cargo that would not fit in the grocery pannier, so I incorporated the head tube rack as I wanted another load point on the front of the bicycle that would least effect the steering.

Q:  Please give us a quick description of the important design features of your cargo bike.

A:

• Multiple loading points for even cargo weight distribution.
• One-key locking system for panniers, cable lock, pump, wheels and lights.
• Center stand with integrated front wheel brace.
• Head tube mounted rack with integrated cable lock.
• Modified grocery panniers for improved weight distribution and reduced wind resistance.
• Handlebar design that blends urban and road riding positions.
• Low stand-over frame design with “up-tube” for enhanced load stress resistance.

Q:  Is there any single feature that made your Manifest entry stand out from the other designs?

A:   I would say that the center stand with the front wheel brace drew the most attention of any feature on my entry. Considering that one of the requirements was a "Freestanding Under Load (while parked) System", I was surprised to see that there were only a hand full of bikes that had custom made stands. Mine was a reversed design that incorporated an additional leg that attaches to the back of the front fender brace/low rider rack to fix the front wheel while the bicycle is being loaded or unloaded. When you want to take the bike off of the stand, you back up the bicycle a few inches and the center stand retracts, catching the front wheel brace along with it. 

Cutter's entry in the 2011 Oregon Manifest Constructors Design Challenge

Q:  I first talked to you about cargo bike designs several years ago, so it is clear you have been thinking about this for a long time.  Please tell us about the evolution of your design ideas and how you arrived at your current design.

A:  The cargo bicycle that I constructed a few years ago (aka the "Loadie") was designed for a friend to replace his ExtraCycle. It was intended for hauling loads around town. It differs from similar rear load cargo bicycles in that it has several pairs of triangulated tubes that brace the rear rack zone of the bicycle frame. The design is not very production friendly, but it is reasonably lightweight and it rides very nicely. To my surprise, the owner has taken it on several extender tours on the pacific coast. It has also done service as a UPS holiday season delivery vehicle.

Detail of "The Loadie"

The bicycle for the Manifest borrowed some of my thinking from the Loadie project and from building another friend an "Amsterdam" bicycle. The Manifest is a collection of ideas that began with other projects and ideas from what I would do differently after completing those projects. I would say that I had as much inspiration from what I have learned from building touring bicycles as I did from building cargo and urban bicycles. Describing my design process as evolution would be fairly accurate. Also, some of the details were from sketches that I made years ago and had saved for the right project. Some of the ideas appeared as I was building the bicycle. I had ordered a box of tamper-proof #25 Torx screws to use for a locking latch on the panniers. After I had the screws in hand, I kept seeing other uses for the screws. That eventually became the "one key" security system on the design.

Cutter's Amsterdam Bicycle

Q:  What design ideas are you thinking about now?  Where do you see your designs going in the future?

A:  The process of designing and building the Manifest entry used all of my spare time and resources for most of last Summer. By the time we arrived in Portland I was very tired and was wondering how I would hold up during the event. The interaction with the other builders was energizing and I found that energy carrying me through the Manifest. To my surprise, I returned home very inspired and ready to get on with the next project. If anything, the Manifest has focused my thoughts on where I would like to take my designs for touring bicycles. It's mostly a matter of refinement, but it's also about having a more complete and integrated package. If I have a signature style of bicycle, it is a 26" wheel format touring travel coupler with integrated racks and fenders. For the future I see myself refining this type of bicycle as well as working with randonneuring and urban/commuter designs. In reality I enjoy building all types of bicycles, as a builder of steel bicycle it appears to make sense to focus on the types of bicycles that lend themselves to a custom fitting and steel construction.

26" Travel Coupler.  The coupling points are subtle.  Can you find them?

Q:  Electric-assist cargo bikes are getting a lot of attention these days, but I was amazed at what people in China carry using only human power.  Would you consider incorporating an electric motor into your design?  If so, what performance characteristics would you hope to gain from the electric assist?

A:  This question really hits a chord. On one hand I am impressed with the performance of an electric assist and the benefits of expanding the number of people that might use a bicycle. On the other hand I look at the added weight of the motor and battery and think that it defeats the simplicity and efficiency of the bicycle. I cannot help but think that if people had lighter weight, higher quality bicycles, they might not see the need for an assist. 

Q:  Your bike has a head tube-mounted front rack, as opposed to a Porteur-style rack that pivots with the handlebars and fork.  Why did you go with this design?  Are you happy with the result?  Have you tried any Porteur-style cargo bikes?  If so, what did you like and dislike about them?
  
A:  I am not a fan of porteur racks. I have built one and I really did not like giving people the option of loading so much weight onto the steering element of the bicycle. I prefer a system that as a first priority will carry grocery bags and I don't see the porter rack as being the best design for this. I opted for a head tube mounted rack on the Manifest bicycle because I wanted to have cargo capacity beyond the four grocery panniers without having a negative effect on the steering. Yes, I was happy with the result.

Cutter's one and only Porteur rack to date

Q:  Last time I talked to you, you were taking a break from building custom frames for customers and focusing more on "soft goods" like bags.  Are you back in the framebuilding business, or are you still focused on other things?  If you are focused on other things, what are they?

A:  I have never really totally stopped building bicycles. I have been sidetracked for extended periods of time working on other projects, mainly packs, tents and other odd projects. I like the diversity of working in different mediums and occasionally combining metal and fabric work into one project. I also prefer to build bikes for people that I know or for people with a specific need, either from fit or by function requirements. I really see framebuilding as a local service to the cycling community. For now I am content to only build a few frames a year.

Q:  Would you like to see your cargo bike design adopted on a large-scale basis?  If Trek came to you tomorrow and asked to license your design, how would you respond?

A:  Yes, it would be great to see some or all of my Manifest entry end up in production. I will be disappointed if a bicycle manufacture does not at least "borrow" something from the design. I would welcome the opportunity to work with a company like Trek. I see it as a chance to be exposed to all of the technology and materials that a small builder would normally not have access to use. Who knows what that might lead too? 

Q:  Are there any "Off-the-Shelf" bikes you think work especially well for cargo hauling?  If so, which bikes and why do you like them?

A:  I really like older steel fully rigid mountain bikes as cargo bicycles. Add front and rear racks, fenders, lights and some grocery panniers and you have a reasonably inexpensive, versatile tool that can do what most people require a car to accomplish. I also like the idea of giving an older, out of service bicycle a second life.

An older steel fully rigid mountain bike, built by Cutter in 1990

Q:  What do you like for breakfast?

A:  My favorite breakfast would be cornmeal buttermilk pancakes, but I usually have oatmeal, cooked with an apple and raisins and topped with toasted almonds and maple syrup.

Yes We Can! (Build Bicycles In America, That Is...)

Defying modern "wisdom," the team at Bowery Lane Bicycles have chosen to build bicycles in the USA. But wait... Not only do they build bicycles in the USA, they build them in New York City, an area renowned for sky-high rents and salaries. This location choice would be remarkable if Bowery Lane were building ultra-expensive boutique bicycles, even though the manufacturing costs of such custom machines might be overwhelmed by the price customers were willing to pay. But wait a little bit more... The hand-built bicycles made by Bowery Lane sell for less than $600!

Any reader who has been following "Cycloculture" for any amount of time knows that one of my primary interests lies in finding USA-based bicycle builders who are offering products at prices which are affordable to "the masses." No company has succeeded in accomplishing this mission better than Bowery Lane Bicycles. I needed to find out why and how the comany was taking this approach. Co-Founder Patrick Benard was kind enough to answer some questions for me.

The "Broncks Black" - Reliable, American-made transportation for less than $600

Q: Why did you choose to manufacture bicycles in New York City? How is that working out for you?

A: My partners and I chose NYC because we live here and managing the manufacturing and launch of this project from anywhere else would have been impossible for us. The fact that the bikes have a certain NYC cache has been a definite benefit though.

Our project really has the history of a cooperative effort that has ended up leveraging the skills and good-will of a dozen professionals (photographers, graphic designers etc.) that we had access to (many in our own building). There are only a few other places in the US where this could have happened.

NYC has allowed us to be very flexible and nimble in every respect except one. Commercial rental space is so prohibitive that it limits our potential as far as retail is concerned.

Q: Describe your manufacturing facility and process, please.

A: We designed the bikes and were fortunate to find a small manufacturing facility in the heart of a West Indian neighborhood with many talented welders. I've said before that we aspire to be the Model T of American bicycle manufacturing and that remains true. Our manufacturing principles are: local, affordable, durable, and stylish.

Q: How many bicycles do you make in an average month?

A: We have made 500 bikes in our two year experience. We are aiming to make and sell twice that in 2011. We also have accessories planned such as front racks, clothing and cycle caps.

Q: Do you see areas for potential improvement, in terms of manufacturing? If so, what are they?

A: A friend once said that the ideal bike was cheap, strong and light and that we should pick two out of these three. Our bikes have not been light. The production we are presently preparing is lighter. Our bikes are relatively inexpensive and we make it a priority to keep it so. Our bikes have been and will be strong.

We also hope to produce more and more of the components locally in the future, chain guards, fenders, racks and anything we can keep in house.

We will continue to innovate and learn keeping our principles in mind.

The "Broncks Raw," All the fun of the "Broncks Black" with clear-coated tubes and brazing.

Q: Please describe your design inspirations.

A: My wife and I visited Amsterdam in 2008. I've always been a cycling enthusiast, and the holiday, the city, the people, and the bike culture inspired me. We wanted to create a Dutch inspired bike that was NYC- street tough. Basically, if our bike can make it here, it'll hold up anywhere...

Q: When someone buys a bicycle from you, what do they get that they cannot get anywhere else?

A: A hand built bike made in America, that's stylish and functional while remaining affordable.

Q: How are your bicycles equipped? What accessories are included?

A: We've tried to offer a complete bike that's ready to ride once assembled. We include a bell, cork hand grips, chain guard and fenders, kickstand, rear rack, as well as our signature wooden crate.

An excellent use for a large cargo box.

Q: What is the price of one of your bicycles? Do you see that price changing in the near future?

A: We'd like to keep a basic single speed bike in the $595 range. We'll be offering a few internal geared versions that will add a bit, price wise, but affordable is our goal.

The "Breukelen," for those who prefer a step-through.

Q: Where would you like to see Bowery Lane Bicycles in five years?

A: I hope to have a five year plan in five years.

Q: What else would you like to say?

A: There are reasons why so little manufacturing is done in the U.S., it's difficult. But it’s important.

The "Reclaimed Crate," a cargo box made from re-used lumber.

Q: What do you like for breakfast?

A: 3 cups espresso, toast with peanut butter and honey from my own hives. Hope the girls (bees) are weathering the cold alright.