Frame Builder Feature: Brian Hapgood of Terraplane Bikes

Brian Hapgood, the founder of Terraplane Bikes, has spent over 15 years perfecting the art of frame building. What began as a childhood dream and a love for downhill mountain biking evolved into a career dedicated to crafting bikes that are faster, smoother, and built to last. Since launching Terraplane Bikes in 2015, Brian has combined his expertise, creativity, and passion for steel to build unique frames that stand out on the trail.

In this Q&A, Brian shares his journey, techniques, and the inspiration behind Terraplane Bikes. Here's what he had to share:

How long have you been building frames, and what inspired you to start?

I’ve been building frames for 15 years. I’ve wanted to build bikes since the third grade, but it was my love for downhill mountain biking and racing that fueled my desire for a better, faster, and smoother bike. My journey began when I kept breaking aluminum downhill (DH) bikes. I started racing for SWD Racing, a company in Modesto crafting steel DH frames. Later, I partnered with Hank at Bicycle Fabrications, who was taking over the fabrication of SWD Racing frames. Hank, a UBI graduate, taught me a lot about the craft. In 2015, I ventured out on my own to start Terraplane Bikes.

Can you briefly describe your frame-building process?

I design frames in Fusion 360 using parameters to ease customization. For fabrication, I use hole saws and a digital angle finder in a milling machine to cope tubes, which I then TIG weld together.

What materials do you primarily use for your frames?

I primarily work with 4130 chromoly steel.

Are there any unique or signature techniques you incorporate into your frames?

Yes, I use a 1 1/2" square tube headtube gusset, hand-sculpted post or IS brake mounts, and stainless steel internal cable guide tubes.

Are there any notable or memorable builds you’ve worked on that stand out?

Two come to mind: a beach cruiser we built for Hank's mom at Bicycle Fabrications, and the custom 160/160mm 27.5" "6 Gun" I built for a friend.

What are some of the challenges you face as a frame builder?

One of the biggest challenges is getting people to buy bikes. Other hurdles include the rising cost of steel and argon, as well as grappling with self-doubt.

What are the most rewarding aspects of your work?

Seeing a pile of tubes and chunks of steel transformed into a functional bicycle is incredibly satisfying. Even better is watching someone shred on a bike I built.

Is there a specific frame design or model you’re especially proud of?

Yes, the Back Pocket hardtail dirt jumper (DJ) with a 372mm chainstay length. It’s the shortest I’ve seen that accommodates 26 x 2.3" tires.

What are your goals or aspirations for the future of your brand?

To continue to build a handful of bikes each year for happy, satisfied clients.

Are there any new technologies or trends in frame building that excite you?

I’m excited by desktop water jet cutters, metal 3D printing, and ongoing advancements in steel metallurgy.

Is there anything else you’d like to share about your brand or your journey as a frame builder?

“To terraplane” means to fly along the ground without wings.

To learn more about Terraplane Bikes, head to terraplanebikes.com and connect with Brian Hapgood @terraplanebikes on Instagram.