Abstract: A method of manufacturing a bicycle fork comprising a steel steering spigot 11, a fork head 12 of fibre reinforced plastic, two fork arms 13 which likewise consist of fibre reinforced plastic and which are formed in one piece with the fork head 12 and axle mounts 14 inserted into the free ends of the fork arms 13 is characterized in that connection spigots provided on the axle mounts 14 are extended by a hard foam core 19; in that the hard foam core 19 is extended in the region of the fork head 12 by a plastic impregnated flexible foam core 22; in that a plastic impregnated flexible foam sheath 20 is laid around the connection spigots 21, around the hard foam core 19 and around the flexible foam core 22; in that subsequently various fibre reinforced sleeves 15, 16, 17, 18 are laid around the foam sleeve 20; in that then the upper parts of the fork head 12 containing the foam cores 22 are combined together into a single steering spigot connection parts 12a and are introduced, at least substantially into the lo

Abstract: A method of manufacturing a bicycle fork including forming a manufactured blank comprising a metallic steering spigot 11, two fork arms 13 and a pair of metallic axle mounts 14. Each fork arm 13 includes a hard foam core 19 at the lower straight portion of each fork arm 13 and a flexible foam core 22 at the upper end of each fork arm 13. Alternatively, a single flexible foam core having an internal pressurization may be advantageously used. The axle mounts 14 have a connection spigot 21 which is inserted into the free ends of each fork arm 13. A polymer impregnated flexible foam sheath 20 is laid around foam core 19, flexible foam core 22 or 37 and connection spigots 21. Subsequently, various polymer impregnated fiber reinforced sleeves 15, 16, 17, 18 are laid around the foam sleeve 20. The upper parts of the fork arms 13 are brought together to form a fork head 12 having a single steering spigot connection part 12a and fork arm transition parts 12b.