On location: Umbrella visits the Brooks saddle factory
Brooks was created by the need to make something better. Legend has it that the company began back in the late 19th century when saddle-maker John Boultbee Brooks’ beloved horse died and he was forced to replace it with a more cost-effective, newfangled invention known as the ‘boneshaker’ – or pedal bicycle. Compelled by the need to upgrade the uncomfortable wooden seat, Brooks used his background in bridlery to create a superior leather version. The Brooks signature leather saddle was born.
Today, the company is one of the largest and most well-respected saddle-makers in the world. We caught up with Works Office Manager Steven Green at its Smethwick factory to ask him if Brooks still possess that spirit of innovation today.
Hi Steven. Has Brooks always been a Birmingham- based company?
Yes. In the early days it was in central Birmingham, just off New Street. It moved to a purpose-built factory in Livery Street (adjacent to Snow Hill Station) in late 1890s. During the war, Brooks even made small parachutes for dropping of supplies to troops on the front line. The move to Smethwick came in 1960 as a result of the Brooks family selling the business to Raleigh Cycles. There’s no-one left at the firm from those days now, but there are a few employees (myself included) who have been here for over 35 years!
The machinery in the factory looks incredible. Was it custom-built?
A lot of the machines still used here at Brooks are old – some date from the Livery Street factory, custom-built for Brooks in the 1950s. Some of the companies who made these machines are no longer in business, so we rely on the expert engineering knowledge of the local area to help out with repairs and spare parts when needed.
“Back in the days before lightweight materials, almost every professional rider chose a Brooks”
Does it all happen in the UK?
Yes, all of the leather saddles and small leather accessories are made in the England, most of them right here in Smethwick.
How long does the production process take?
It takes more than a day to produce a Brooks saddle. Although there’s a considerable amount of waiting involved as we wet the leather and then dry it.
It’s a step-by-step process. First we make the metal components and plate (or paint) those. Next, we assemble the frame and create the leather top, and then finally rivet the leather to the frame.
How many styles of saddle do you currently produce? What’s the most popular?
There are around 25 different models, each with their own particular leather colour and frame finishes. In the UK, USA and Japan the classic Swift and Swallow saddles are the best-sellers, whereas in Holland and Germany the models with springs are the most popular.
Germany is the nation that buys the most, but the USA is not far behind. Then come the UK and Japan. Other countries have shown increased interest in recent years like Norway, Australia and Thailand.
Is it true that race riders use Brooks even though there are lighter alternatives available?
Back in the days before lightweight materials, almost every professional rider chose a Brooks. The way the side flaps were redesigned was born from requests from pro racers who sought extra clearance for their thighs during a sprint. These days weight is a key consideration and unfortunately leather is a little too heavy to race with. However, we do now produce a Cambium saddle which has a carbon frame and reduces the weight by around 40 per cent.
How long does it take for a saddle to mould to the rider’s behind?
Ha-ha! This is the question I get asked almost every day, and unfortunately the answer isn’t so straightforward.
Firstly, the weight of the rider will make a difference. The heavier he or she is, the quicker a saddle will mould to their shape.
The duration of the ride is another factor. A longer ride time will allow a gradual and natural heat transfer from backside to leather, and the warming leather will mould easier. Lots of short rides do not achieve this warming effect. Ambient temperature also makes a difference as hotter weather allows the leather to become more supple.
Finally, model choice. Some models are more rigid than others because of their shape. For example, the Swallow moulds easily because of its narrow front end and lack of side flaps, but by contract the Colt is one of the most difficult because of its deep sides. Generally, the wider the saddle the quicker they are to break in.
Pictures by Handover Agency.