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Gaerne: Behind The Scenes

In the first of a new series on, we take you inside the industry to show just what goes into making some of the products used by prod and weekend warriors alike.

First up is Gaerne, who have been hand-crafting quality boots for over fifty years since the company started in 1962. Situated near Treviso, Italy, in an area synonymous with quality shoe making, the Italian company continues to use the highest quality leathers and the strongest and most durable materials while other brands have outsourced to China and the Far East.

Whilst they have grown over the past fifty-five years, something that has not changed at Gaerne is their address.  This is because they believe in old fashioned quality, a quality that comes from Italy.  Having taken the trip around their factory it is clear to see also. Every step that goes into making their innovative SG-12 boot is undertaken with painstaking attention to detail, by people that have worked for the company for 30+ years.


The SG-12 boot is compiled from 218 crafted parts. It includes a Dual Stage Pivot System, which is exclusive to Gaerne


Gaerne produces some four hundred shoes each day. Here you see their latest cycling shoe, the Carbon G.Stilo+


All Gaerne athletes benefit from their own modelled foot form, so their boots are tailored to their exact requirements.  Here we see the forms for Suzuki World MXGP riders Kevin Strijbos and Arminas Jasikonis, alongside those of Martin Davalos.


The process begins with the cutting of each panel. The leather is first printed and then stamped, using a traditional die-cutting technique used in the shoe industry since the mid-nI eyes the century. Here you see the branded inside leg panel of the SG-12 boot.


Once cut, the panels are stitched together by hand. Here we see the upper part and front panel that uses a Swiss breathable fabric called ACRONOS.


The cycling shoes are then heated to soften the leather, before being placed in a machine that stretches the uppers around the foot form giving the shoe its basic shape.


The inner soles are then glued into the boot before the leather is stitched. The SG-12 design features a slimmer shape in the toe area for an improved feel of the shift lever and the bikes controls. The entire area is wrapped by a new plastic material that is lighter and provides more comfort and feel for the bike as well.


This might look like something from a horror movie, but it is actually the machine that presses the upper shoes and prepares them to receive the final sole.


This computer is programmed to receive the shoe, ready for the final sole. The computer is programmed based on the model of shoe and the shoe size.


Here we see the carbon soles of the G.Stilo+ cycling shoe


Once the final sole is adhered to the boot, it is time to trim the final parts of the boot back.


At this point, the upper boot and sole are largely complete, except for a few key finishing touches. Firstly, the steel toe cap is fitted.


Then the final wishbone anti-torsion protection system is fixed.


Leaving only the Gaerne-branded pivot screw kit to be installed.


At this point the boots are thoroughly cleaned and inspected before the final boot straps are fitted.


The boots are then boxed and loaded into the vans ready for distribution to another happy customer.


Gaerne athlete Malcolm Stewart with the Fluo Yellow SG-12 boot.

Words: ConwayMX | Lead Image: ConwayMX