New for 2007 is a redesigned ‘Flite’, and a new bigger bolder brand name on the side of every saddle.

I’d never seen how saddles are actually made, and admit I’d never really given it much thought, but as my meeting with Selle Italia drew closer, my mind began to fill with wonder…

The far end of the huge boardroom table was covered by historic saddles made by Selle Italia. Some of these were ancient, and I imagined had seen battle in some of the earliest Tours and Giros.

Apparently back in the day, weight was given secondary status to adding springs to cushion the ride (‘cushion’ being a relative word).

Apparently some saddles were used as torture devices. One wrong step here and it’s game over.

IMPRESSIVE PALMARES
Few saddle makers can offer the history and palmares of Italy’s Selle Italia – a connoisseurs brand, if you will. It’s a safe bet that visually everyone of us has ridden on one of their saddles at some time.

The stats themselves are enough to inspire impressed chin rubbing:
• The company was founded in 1897 - that is 110 years ago!
• 1970 – First to use plastic shell on bicycle saddles
• 1974 – Introduced foam to replace hard leather covers
• 1979 – variable thickness on saddles shells to increase flexibility and comfort
• 1980 – Turbo launched – first with anatomic contours
• 1984 – Patented shock absorbing pads between rail and shell
• 1987 – First lightweight hollow rails patented
• 2004 – Axiol Pivot System introduced on Signo models

The Signo saddle ‘pivots’ from side to side where the rails meet the shell at the rear – a comfort enhancing innovation.

The gel bumpers between the shell and rails are another Selle Italia patent.

Like so many Italian cycling company offices, Selle Italia’s boardroom is adorned with an impressive display of jerseys. I sure do like that striped one.


And some more impressive stats you probably did not know:
• They supply saddles to more than 200 OEM brands worldwide – so you’ve probably ridden a Selle Italia saddle without even knowing it.
• 100% of their production is handmade in Italy.
• The made over 2,100,000 saddles in 2006 – more expected for 2007
• 89% of their saddles are exported worldwide

• Rolls and rolls of sweet smelling leather. When every saddle you make is covered in genuine leather, you need to keep a lot on hand. This was just a small part of the leather room.

• Leather is purchased as complete hides, and cut to size for each model.

• A box of Yutaak mtb saddles awaiting rails.

• Alongside the leather you can find rolls of carbon fiber sheets, ready to become the shell of your next saddle?

• Rails are attached to saddle shells in the factory.

• The rails are pressed into place on this machine, which presses the nose cap into place.

• Hot air is used to set the glues in the last step before boxing.

INTO THE TEST ROOM
One of the most impressive parts of my tour was the ‘test room’ – it’s exactly where each model is tested to meet the company's safety, durability, and strength requirements.

• Leather is tested here to ensure durability meets their standards.

• Rails are tested for strength and durability on this machine that essentially hammers ‘em with various weights.

• Saddle covers are tested here, by measuring deformation after impacts from various loads.

• The Oven – you guessed it – nothing like a little heat to find the breaking points for materials and adhesives. It’s also great for toasting up those lunchtime paninis.

• In an old carboard box in the test room is a bunch of old saddles from various ‘testers’… check out the names on these ones. Some famous butts were here. Pantani, Ullrich, Rebellin... the list is long.

• A number of the test saddles were marked with these grids – used by riders to identify specific areas of pressure, or places to modify shapes. As unscientific as it might sound, when it comes to something as personal as how a saddle feels - is there a better way to gather rider feedback?

• Coming soon to a bike shop near you – the all new, mostly carbon tri- and TT- saddle, which incorporates a moulded-in bottle cage designed to smooth airflow at the rear of a rider. The rails are also made to allow a more forward position on the bike.

• Still in development – a new take on rail design – just mold ‘em into the shell.

• Can you imagine the discussion that led to this…? Me neither.
Coming to a trade show booth near you… ...