Inside the Brompton Factory: The New G Line Electric Bike | Fully Charged

We were invited for a VIP tour of the Brompton factory earlier this year — and it helped us make the call.

Out of over 500 eBike brands, Fully Charged has handpicked the world’s top 10. The new Brompton Electric G Line made the cut.

In this behind-the-scenes video, Fully Charged founder Ben visits Brompton’s iconic West London HQ to see how the new G Line is built from the ground up. With a reengineered frame, better weight distribution and wider dropouts, this latest version is a huge step forward for one of the most recognisable folding bikes on the planet.

After 50+ Fully Charged customers have already taken delivery, the feedback has been outstanding — and it’s easy to see why.

🔍 Bike Featured in This Video:

Brompton Electric G Line
https://www.fullycharged.com/brompton-electric-g-line
Designed electric from day one: improved geometry, smarter weight balance and all the portability Brompton is famous for. A compact eBike for modern urban life.

⚙️ What to Expect:
• A full tour inside Brompton’s UK factory
• Exclusive insights into the G Line redesign
• How Brompton reimagined the Electric from the ground up
• Why this model earned its spot in the Fully Charged top 10

📍 Available now at Fully Charged London and regional partner stores.
🚲 Book a test ride in London Bridge, Silverstone, New Forest, Guildford or Cornwall:
🔗 https://www.fullycharged.com/test-ride-an-ebike/

🧠 Urban eBike Tips:
• Foldables are ideal for mixed-mode commuting and tight urban spaces
• Always test ride before you buy — how it feels matters
• Look for electric bikes built from the ground up, not retrofitted

👍 Like, comment, and subscribe for more eBike reviews, factory tours and insights from the Fully Charged team.

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hello everybody today we are here at the Brmpton factory in West London and uh Alex is joining us and uh he’s going to give us a little um tour of the factory and and we’re going to learn a little bit more about the Gline and what it has to do yeah welcome to Brmpton uh I’ve been here now 4 years as one of the manufactur engineers and we’re going to get a real deep dive into how we process the bike around our factory so we’re going to learn a little bit about what the difference is between the Gline and the Cline and the Gline is obviously their new ebike which has been purpose built these are the Gline so here we’ve got our Gline frame set here we can see our slight small changes that we’ve made to our main frame so to accommodate for the slightly bigger wheel size we’ve gone for a slightly bigger mainframe tube we’ve got slightly different bend radi to keep that fold the same and what we have made to change here at Brmpton is we’ve got our new hinge design from our core to our G line so it’s just thicker stronger an anti-rot anti-rotation hinge clamp as well on which we comes together in assembly as like a an extra additional feature to the bike we also have slots here for our bottom bracket to put our torque sensor in and you can see here these are the guys that are brazing the frame so they’re using a brass yes so we use a a brass alloy here at Brmpton and simplest way to explain it is we’re we’re gluing our bike together and we’re feeding that wire into the joint here to give us that nice bond when we’re bringing together our hinges to our bike this is one of our most stressed bits of our bike is we want to make sure we get the best bond on here so what we have here is now our next gen auto braze machine effectively what we do is we preheat this big blob of metal and also our tube a little bit and what we do is there’s a sweet spot temperature where we this braze ring sits inside when the flame’s pulse that was a sweet spot where that’s just melted we’re just waiting for the preheating and cooling stages so your hinge is red hot there and then it comes around to being air cooled and then water cool using the capillary action effect inside the hinge basically the heat sucks and melts the the braze ring and we get that nice uniform bond we’ve got a lot of uh carbonization on our hinge so all parts will go into rumbling and what will happen is it’ll just polish up this surface around the hinge clean it up and it allows us then to get a nice paint finish on our tubes and that’s important as well for any further bits of brazing that we need to do for our 20-in wheel we’ve introduced a brand new wheelb line for that so we have a four stage assembly process here our first main stage here on site is we’ll hub fill our hub with our sp uh spokes and then this machine here will then help us lace our wheel together the wheel will get built to about 70% of its truness here and then what it’ll do is it’ll go into first stage here rim taping so this rim taping machine allows us to give wheel sets that are tubeless ready and then it will then go into trueing here uh where we’ll bring our wheel into pretty much 100% tuner so it’ll get rid of any hop or stroke that we have so here our chewing robot is a set of lasers which will read the wheel and then there’s an algorithm built within it that then knows which nipples it’ll need to adjust so one of the big differences is the the new hub that they’re using on the Gline and being laced into a 20in wheel so what we went with in Gine is an electric rear wheel so with that we have four-speed on the rear uh and the power Yeah comes from our rear wheel big design change for us and also completely new electric system which we’ve launched with Gine which again gives an improved ride feel yeah so you’ve obviously got the weight distribution now much more balanced with factory in front we’ve brought in an automated tire fitting machine for for us to fit our tires oh this is a G line here yes so this is Gine assembly line all our frame components will arrive here in paint and then what we’ll do is we send them around the paint plant we’ve got a powder coat paint facility here on site so we’ll complete your order here on site to order we don’t hold any stock of bikes just again cuz those configurations powder coating so we negatively charge our parts positively charge our powder you can see here we’ve got an operative getting into the tight nooks and crannies of all of our parts and then we have an automated arm here which then does that final coat and then it’s important as well once it’s been painted paint’s just not set so it goes into it storage boxes we’ve gone for a slightly thicker matte kind of textured shine to our paint so we’re going to head now to assembly where we’re going to start to see our G lime be made so we have a little preassembly channel here where once we come off paint we’ll get our decals put on everything will get reamemed and tapped to give us that tight tolerancing we want on our hinges line one currently is our just steel frame seine production line here we’re producing 300 bikes stay off this line so we run a tact of a minute 42 seconds station 15 is our king pusher they’ll push everyone else will follow and everything will move around together slightly different assembly process here for Gine we’ve got 12 stations uh and we’re running about a 5minute tact so a little bit more work content on some stations here on the line but um those less stations mean we have a little bit more preassembly over here for our G line so the biggest changes between this and the Cine uh obviously is the fact that now this is a rear wheel rear hub motor correct um and the batter is on the front correct so as before it was all on the front and you’ve got a better weight distribution absolutely so we now route our our controller now sits in this patch here historically used to sit on the front here that’s now integrated close to our motor and we also have from our battery internal cable routting which will come out and power our rear motor so this then is also our torque sensors set here in our bottom bracket again all inter links with our controller kind of neatly brings all our system together and gives you that real good ride feel so to accommodate for your rotor rear electric hub and your gearing we have wider dropouts on our rear frame again because our bike is specific to us all our tooling is custom made for us so again allows us to fully articulate our bike how we need it damped as well for safety and again allows the operative to work in and around the bike super easy in assembling uh and setting up everything we break our bike down into this 20digit code here and each code represents a different breakdown of our bike about 85% of our product now we export 15% is in the UK 35% of our bikes now go to APAC and the rest is Europe and the Americas 100 G lines a day we want to ramp up to 150 G lines in the new year just over 2,000 bikes a week of that 1,200 C line about 400 G line and the rest is P line T line and our C electric and P electric did you say you can have 20 million million different types of Yeah exactly so a lot of different models different colors different lighting configurations different handlebar types so one color one type becomes Yeah hundreds of different sophisticated yeah absolutely are you okay [Music]