• I do wonder if the frame is durable with this type of construction

    Ask a Honda Cub owner. OK, the Cub and previous pedal cycles welded together from pressings have been steel, but the car industry has been building frames this way from aluminium for a while now.

  • Sounds promising Tester, thanks. At first glance the welds they show seem fragile, but if you say so that the Cub was built in similar fashion, I'm convinced. Aluminium or not ;)

  • the welds they show seem fragile

    The forces trying to pull two clamshell halves apart halfway along a box member are not the same as the forces trying to rip a tube clear of its moorings at a junction. It's mostly shear, and the weld is much longer. Stacks of dimes not required.

    Strictly speaking Cubs have a tube joining the headstock to the rest of the frame, so they're not fully pressed, but the bigger and faster 1950/60s Benlys were pressed clamshells, as were the Dax monkey bikes among many others. Even the mighty Yamaha R1 is just a bunch of aluminium pressings welded together along the edges 🙂

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