Visit & Test | Zafi Cycles: a Belgian wooden gravel, really? ⋆ Vojo

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As surprising as it may seem, Zafi is a Belgian brand producing wooden bicycles! In addition to being ecological, the wood used coming from the forest located a few kilometers from the brand’s workshop, Zafi explains that this brings various advantages on the ground. We went to meet Simon Malvaux, co-founder of the brand, who opened the doors of his workshop to us for a morning. We finally left with a gravel model that we put to the test on our usual test routes for several weeks. What could a wooden gravel be worth on the ground? Verdict:

If gravel has exploded in recent years and its popularity continues to grow within the small world of two-wheelers, a chassis made of wood is, however, much less common. If we have already told you about a wooden MTB model in the past (cf. Getting started | Suji Drop Workshop: a wooden bike, how does it ride?), it is here towards the gravel segment that Zafi has turned.

Based in Walloon Brabant, a few kilometers from the Belgian capital, Zafi is a young Belgian brand founded in 2021 by three recently graduated friends: Simon, bioengineer and cyclist since a young age, Johan, bioengineer and passionate about woodworking , and finally, Loïc, industrial engineer keen on technical challenges.

It was Simon who opened the doors of the Zafi workshop to us to introduce us to the history of the brand, their bikes and especially the manufacturing process of these funny frames.

Often, bicycles are made with raw materials that come from far away. I wanted to bring this know-how back home.

Simon, co-founder of Zafi

« Often, bicycles are made with raw materials that come from far away. I realized during Covid that we were dependent on this foreign workforce and I wanted to repatriate part of this know-how back home. This is the reason that pushed us to try to make a bike with local materials. Wood being a fantastic material, particularly in its capacity to absorb vibrations, in its ease of work or even in its visual signature… We thought why not try! », Explains the co-founder of the brand.

« It was by chance that I discovered the concept of a wooden bicycle on the internet. Having always been passionate about bicycles, I took on the challenge of making one myself, for myself. My studies taught me 3D modeling for design and I am familiar with bicycle geometry. On the other hand, I didn’t know much about assembly techniques, so I inquired with professionals and carpenters, and I finally made around ten prototypes in walnut and ash. We then launched a crowdfunding campaign which was successful, and we began the production of our various orders, the Zafi adventure had begun! », continue Simon.

The name of the brand refers to a people from Madagascar called the Zafimaniry, characterized by impressive woodworking know-how and direct victims of deforestation. Nice wink, especially for an eco-responsible brand!

Visit: when passion meets functionality

Who says wooden bike, obviously says choice, storage and drying of the raw material… which turns out to be wooden logs coming from the Soignes forest, on the outskirts of the Belgian capital, and a few kilometers from the workshop of the brand. “ With one trunk, we make around fifty frames », specifies Simon. “ The trunks are cut into planks, which are then stored here for a certain time so that they dry properly. This prevents the wood from working once transformed into a frame. », he continues.

Simon works with two species of wood to bring his frames to life: ash or walnut, each having a slightly different visual signature as we will see a little further down.

« Like metals, each species of wood has its own properties, and some are therefore more suitable for creating a bicycle. We chose walnut and ash because they are two species that have proven themselves in the sporting world, such as baseball bats, tennis racket handles, hockey sticks and even skis. These essences are capable of filtering vibrations and deforming without breaking », explains Simon.

But between raw wooden planks and a bicycle frame, there is a world of difference! The first step is to cut these long, dried wooden planks into standard size planks ready to be made into a frame.

These slats are arranged in a precise manner, in the form of a stack of triangles and by carefully analyzing the wood fibers in order to take maximum advantage of the unique properties of the material: “ Wood has interesting intrinsic properties; it naturally absorbs vibrations. As with composite materials, depending on whether you work parallel or perpendicular to the direction of the fibers, it does not work in the same way. », explains Simon.

Thanks to a 3D drawing of its frame, it is machined with a digital milling machine. This cuts the frame with great precision from these assembled boards. It’s actually a two-step process since this assembly of boards only creates one half-frame.

The machine is already very precise, which makes Simon’s finishing work easier. The frame, or at least half of the frame at this stage, is hollowed out internally with two objectives: to obviously save weight, while retaining the necessary strength, and to allow the internal passage of the sheaths. To do this, aluminum sheathing is used to guide the cables through these different “boxes” at the heart of the tubes.

We can continue to evolve our framework, particularly in terms of weight.

Simon, co-founder of Zafi

This is a point on which Zafi believes he can still significantly evolve: “ Currently, all our frames are ISO4210-6 certified. We believe we can continue to evolve our frame, particularly in terms of weight by continuing to reduce the material inside the frame. Currently, the framework (Editor’s note. in size 58) is 3.3 kg while the complete bike ranges from 9 to 12.5 kg. »

Left side, right side… These two half-frames are then glued to each other to form the frame. Although this is barely visible once the varnish is applied, a line of glue nevertheless holds the two parts of the frame together.

For the rear triangle, thinner boards are heat-bent, before being placed in a pressing jig under a hydraulic press.

Simon attaches the rear bases to the front triangle, using a classic framer. The junctions between the chainstays and the stays are parts developed in-house, while the other fixing parts (derailleur, brakes, etc.) come from Paragon Machine Works, an American company.

And now the framework is taking shape! Last step: finishing, with your choice of matte or glossy varnish. “ This is the advantage of making a bike à la carte, you can adjust it according to the customer’s wishes. We can imagine changing the color of the logo, making an ash line in a walnut frame… We also make custom frames, but it depends on the client’s expectations and needs. », Explains Simon.

In an ideal world, I would like to work only with European components

Simon, co-founder of Zafi

« Either way, every setting is a meeting with the client. In addition to choosing the type and finish of the bike, we define specifications together with the customer. Depending on your needs and preferences, you adapt the bike (the clearance for the tires for example) but also the choice of components. In an ideal world, I would like to work only with European components, but at the moment this is not yet the case », Finishes the man behind Zafi.

To guarantee the quality of its bikes, Zafi only sells frames assembled at this stage. “ If the customer wishes to integrate parts that he or she cares about, it is always possible to make arrangements », nuance Simon. The entry ticket to obtain a Zafi bike is €4,500, then it is the choice of more high-end components that pushes the price up.

Simon’s goal is to extend the range – it is not impossible that the brand is considering a mountain bike as well as an e-bike – but to remain in artisanal production and maintain direct contact with the customer for him offer a framework that meets their needs as closely as possible.

Zafi Cycles Gravel : le test terrain

Now that we know how these curious wooden bikes are created, it’s time to put one of them to the test on our usual test circuits. Does wood have a real advantage on the ground? How does this material react on the trails? Is it capable of correctly filtering shocks and vibrations from the terrain? Verdict!

For this field test, the brand made this magnificent ash model available to us for several weeks. Let’s quickly take a look at the owner!

While everyone will appreciate the shapes of the frame according to their own tastes, it’s impossible to remain unmoved by this wooden frame (have you got it?) and its magnificent finishes: wood design, junctions between the different structures of the frame, marked angles… We are as much faced with a pretty object as such as we are with a bicycle.

Like a multitude of components on this model (seat post, cockpit), the fork comes from Ritchey, with a carbon WCS Adventure. It is compatible with tires up to 48 mm in section and has 3 multi-function mounting holes on each side to accommodate luggage.

Sram takes care of the transmission with a Rival 1×11 mechanical groupset with 10/42 cassette associated with a 42-tooth chainring at the front. Nothing extravagant but a reliable group that gets the job done!

The brakes are Sram Rival with 160mm discs front and rear. Here on the other hand, there is something to complain about because the power is a little tight for our taste, and the feel of the levers is not as convincing as with Shimano.

The running gear is also Belgian-Belgian with a pair of wheels signed Enigma. Founded in 2019 by Manu Lhoir, a former professional road racer, Enigma Wheels offers a comprehensive catalog of artisanal carbon wheels. This is the Nova model with a height of 38 mm and an internal width of 25 mm which equips our test model. The tires come from Vittoria with the Terreno Wet model, a smart choice given the conditions in which this test was carried out.

In terms of geometry, the Zafi (in size 54) is characterized by a fairly large stack (56 cm), a comfort factor by straightening the cyclist’s position, a steering angle as well as a seat tube angle of 72.5° and 430mm bases. Quite classic dimensions, but entirely in line with contemporary gravel.

The first thing that struck us about this Zafi is its comfort… or more particularly the impact filtration offered by the chassis. For a first experience riding a wooden bike, we didn’t know what to expect and our only points of comparison were the other materials used in the world of mountain biking and gravel (carbon, aluminum, steel or even titanium) . The Zafi offers this sensitivity on small impacts (gravel, small breaks in the ground, porous coating, etc.) which is very appreciable on longer outings. Riding comfortably means riding longer!

Wood filters differently, as if it were eliminating vibrations by digesting them within itself…

It is difficult to compare with other materials usually used in the manufacture of gravel frames, as each bike offers its own feeling: two carbon bikes for example will not have identical properties, and it is therefore difficult to compare. generalize a behavior only in light of the material used. We will therefore suffice to say that the rigidity of the frame is comparable to that of a carbon bike, with the natural damping characteristic of steel or the softness of titanium. More concretely, wood filters differently, as if it were eliminating vibrations by digesting them within itself… which is considered good filtration since you feel (almost) nothing as a pilot. We can say that this is one of the most comfortable gravel models we have tried so far.

Without being disappointing, the Zafi is not the most explosive model we have ridden as such. The pedal stroke is easy and the bike responds well, we do a series of hard restarts without problem but we still feel that we are not on a hyper sporty gravel like the BMC Kaius where the Scott Addict Gravel when it is necessary to continue the effort.

The position offered by the Zafi is pleasant and you are well set up to pedal for long hours. The rider’s weight is well distributed, and helped by the good set of tires, we have very good traction even on more technical and rough climbs.

With this good shock filtration and this pleasant position, we couldn’t resist the desire to take it on more chaotic and almost mountain bike-style singletracks, and the Zafi did largely well. Beyond the material, the geometry of the chassis provides the right mix between stability and handling. On small, fun trails, the bike is sufficiently manageable and really pleasant to ride, without however being able to challenge the gravel models on the border of mountain biking… It’s all a question of compromise, and Zafi understands that well!

Verdict :

Before being a pleasant chassis for racking up the kilometers, the Zafi gravel is above all an adventure: a human adventure with the artisanal and eco-responsible project in the background, but also a matter of passion! It was the love of cycling that brought Simon Malvaux and his two sidekicks (Johan and Loïc) into this project where wood and gravel mix in an astonishing combo. Impossible to remain unmoved by this magnificent chassis and its multiple details and finishes; the Zafi is as much a pretty object as it is a real, more than functional bike!

Beyond the local, original and aesthetic side, the use of wood for this segment of gravel brings real dynamic qualities if the species is well chosen and well implemented. With its natural capacity to absorb vibrations and (small) impacts, the wood used in the construction of this Zafi (walnut and/or ash) provides a lot of comfort once on the ground. Add to that a pleasant position, good performance and behavior providing a lot of riding pleasure, and you have this Zafi built for adventure during long days in the saddle!

For more information : https://zaficycles.be