In this conversation, Craig Dalton and Jim Santos delve into the origins and evolution of Outer Shell, a cycling bag company based in San Francisco. They discuss the Bay Area's coffee culture, the shift in cycling trends towards comfort and convenience, and the thoughtful design and material choices that set Outer Shell apart. Jim shares insights into their product line, warranty policies, and the challenges of scaling production while maintaining quality. The discussion also touches on unique products like the Magic Musette and Pico Pannier, highlighting the brand's commitment to innovation and customer satisfaction.

Takeaways:

• Outer Shell started as a response to a local coffee culture in San Francisco.
• The company was founded by Kyle, who has a background in mechanical engineering and a passion for cycling.
• Sewing allows for creative freedom in product design compared to other manufacturing methods.
• Cycling trends have shifted towards comfort and carrying more gear for enjoyment.
• Outer Shell aims to be the second or third bag purchase for customers, focusing on quality and design.
• The materials used are rugged and designed for durability, with a focus on repairability.
• The company offers a lifetime warranty, emphasizing customer service and product confidence.
• Production is done in-house, allowing for quick adjustments based on customer feedback.
• The brand explores unique colors and patterns, often inspired by current trends.

Chapters

00:00 Exploring the Bay Area Coffee Culture

05:03 The Birth of Outer Shell Bags

09:56 Shifting Trends in Cycling Gear

13:53 Product Line Overview and Design Philosophy

20:19 Material Choices and Warranty Insights

27:45 Scaling Production and Future Plans

32:41 Unique Products: Magic Musette and Pico Pannier

In this special “lost episode,” I sit down with Sam Alison, the founder of Singular Cycles — a UK-based brand that’s been quietly ahead of the curve since 2006.

Sam shares how his journey from Australian shop rat to UK-based frame designer was shaped by a lifelong love of bikes, and how his early experiments with 29ers and drop bars paved the way for what we now call gravel bikes. We talk about his iconic models like the Swift, Peregrine, and Griffin, the rebirth of Singular with titanium offerings, and his philosophy on timeless design, frame material, and rider-first geometry. Whether you’ve seen a Singular bike roll by and thought “what is that,” or you’re just curious about the origins of modern gravel geometry, this conversation is well worth the listen.

🔧 Topics we cover:

• Sam’s early days in Australia and the 90s MTB boom
• What inspired the first Singular frame Drop bars on MTBs and the road to 29ers
• Why steel (and now titanium) still matters
• Designing for versatility without compromise
• Thoughts on “gravel” as a category — and where we go from here

🚲 Learn more about Singular: https://singularcycles.com

📸 Follow on Instagram: @singularcycles