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Updated: Allied Adds Ultra-light + Adjustable DUET Cockpit System, Lighter BC40 & Signs Courtney!

Kate Courtney Allied BC40 riding
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Arkansas-based Allied Cycle Works has announced a groundbreaking partnership with American cross-country mountain bike champion Kate Courtney and her She Sends Racing program. Courtney recently parted ways with the SCOTT-SRAM program, which she called home for the past six years. This new collaboration, however, hits a little closer to home and highlights Courtney’s mission-driven initiative to empower women and girls through mountain biking—while showcasing the Allied (and 100g lighter) BC40 mountain bike race machine. 

Are Allied Bikes Still Made in the USA?

allied cycles pass through door from layup to molding rooms
Photo: Tyler Benedict/BikeRumor

We contacted Allied and Drew Medlock, Allied Cycle Works CEO, for a statement after many comments on this piece to get the correct info.

“As part of our ongoing commitment to deliver higher quality products, improve availability, and move faster on product development, we have streamlined our in-house manufacturing processes on the updated BC40. While all development and testing remain in-house, we now partner with an external factory for the carbon layup of the BC40’s front and rear triangle.  Each frame then undergoes a rigorous in-house quality inspection and paint preparation to ensure the highest standards. Finally, the frame is custom-painted and assembled to each customer’s unique order-just like every ALLIED always has been.  We are confident this new process will result in a better product for the rider.”

Drew Medlock, Allied Cycle Works CEO

Kate Courtney Allied BC40 long
Photos: Allied Cycles

Kate Courtney Joins the Allied Family

Kate Courtney is a household name in cross-country mountain biking. She is the 2018 UCI Mountain Bike World Champion, two-time U.S. XC National Champion, and Tokyo 2020 Olympian. Known for her historic 2018 World Championship gold (the first American Elite women’s win in 17 years), she embarks on a new chapter with Allied Cycle Works.

Courtney will race the 2025 season aboard the newly refined BC40 mountain bike. Courtneys program, She Sends Racing, ties into to the She Sends Foundation, a nonprofit established in 2023. Courtney’s schedule has not been released, but we expect a full roster of XCO racing, though the She Sends Racing is new to the World Cup scene. Courtney alone carries a impressive 1,474 UCI points and is currently ranked 9th in the world.

Allied BC40 bottom side

She Sends Racing Partners

Who else is Courtney partnering with for her She Sends Racing Program? She made an announcement two weeks ago that she is partnering with electric vehicle manufacture RIVAN – so that one we know for sure. In her photos, she sporting a full Rapha kit and RedBull helmet, so we can assume they are both in for the 2025 racing season. The tires look to be Schwalbe, which will be a new tire for Courtney who has ridden Maxxis previously under the SCOTT-SRAM banner the last six years. It will be interesting to see who else jumps on, and what her racing program will be this year.

“I’m thrilled to partner with Allied and race the updated BC40 this season. From the first test ride, I was blown away by its performance. It’s exciting to bring this American-made brand to the World Cup stage.” – Kate Courtney 

Allied BC40 FA

The Updated Allied BC40

The BC40, Allied’s cross-country race bike, now features a 100-gram weight reduction. Where does the reduction come from? Allied told us it’s from an updated carbon layup and bottom bracket. We’re hoping to see one for ourself sometime soon and get the full lowdown.

To complement the BC40, Allied is also debuting its innovative DUET lightweight handlebar and stem system. Designed and manufactured in-house, the DUET cockpit combines weight savings and adjustability in a two-piece setup.

Duet Cockpit front

DUET Handlebar and Stem

The DUET system solves a longstanding challenge with traditional bar and stems clamps. Ones that require carbon handlebars to be overbuilt to endure clamping forces. Allied’s redesigned clamp system distributes forces more evenly, allowing for a lighter, more refined design without compromising strength. Unlike one-piece carbon bar/stem setups, this two piece system allows for adjustments for wrist angle and profile.

Key details include:

  • DUET Handlebar: 780mm carbon bar, optimized for use with the DUET stem – 135g
  • DUET Stem: CNC-machined aluminum stem – 64g (50mm)
  • Integrated Computer Mount: 3g
  • Total Weight: As low as 199g, lighter than most integrated systems while maintaining adjustability
  • MSRP: USD 325

“We reimagined the handlebar and stem interface from the ground up. With real-time design iteration and in-house machining, we’ve developed a system that outperforms integrated setups while offering the flexibility of a two-piece design.” – Sam Pickman –  Allied’s Director of Product and Engineering.

For more information on Kate Courtney, the updated BC40, and Allied’s DUET handlebar and stem system, visit alliedcycleworks.com.

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23 Comments
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jmed
jmed
30 days ago

So an XC version of a 5DEV stem?

Last edited 30 days ago by jmed
VazzedUp
VazzedUp
29 days ago

Looks like my old quill stem and a standard modern stem mashup.

Michael
Michael
29 days ago

Might want to check, but I believe the new BC40’s are made overseas

Steve
Steve
28 days ago

This is a major bummer. That bike was on my list to be my next XC bike. Wanted to support US manufacturing since there’s not much left. Looks like that list is down to the Ibis Exie USA for a carbon frame.

Veganpotter
Veganpotter
28 days ago
Reply to  Michael

The Walton legacy in action

Cheese
Cheese
28 days ago
Reply to  Veganpotter

Always low wages.

tech9
27 days ago
Reply to  Michael

Exactly Michael.

I really wish they would be a LOT MORE TRANSPARENT about the fact they are not made in the USA any more. I get it, its hard to be competitive in this market, but it’s also very misleading that their website still makes you think it’s made in the usa. The van you see driving all over bentonville still has the “made here” in the silhouette of the USA.. It’s kind of cringy.

Veganpotter
Veganpotter
24 days ago
Reply to  tech9

With new ownership, they could easily still be made locally. They don’t need massive margins. Obviously they want them though. Would have been better to just keep raising prices and stay a made in the US boutique brand

Craig
Craig
29 days ago

That “Adjustable Cockpit System” is what we’d call in the days of Prohibition a “handlebar and stem”. My how times are a changin’.

Looks cool though.

xalt
xalt
29 days ago
Reply to  Craig

ok, but it has a simple and clever integrated computer mount.I want one just for this !

mgs
mgs
29 days ago

About the only thing worthy of note here is the name, clever…. I’ve never understood the hate toward one piece bar/stems. They look awesome and work great. Everything is a compromise anyway and I’ve never failed to adapt to the slight geo difference between two brands for common sizes. And… why is Kate’s bike the only on without Flight Attendant?

Joe
Joe
29 days ago

the world wasn’t waiting for another overpriced „american-made“ brand…Extralite 50mm stem 52g
Darimo 780mm handlebar 101g
Darimo Epsilon 150g
Gemini Pröpus 160g
GrigioCarbonio 125g
and many more handmade in europe..
so nothing special to see here.

Greg
Greg
29 days ago
Reply to  Joe

Extralite stems are not kind to bars. That said, there’s the Newmen 318.2 stem, Intend Grace, Darimo’s own IX2AL, and I’ll throw in the BikeYoke (even though it only comes in 35mm clamp).

Veganpotter
Veganpotter
28 days ago
Reply to  Joe

None of these brands are interested in being adopted by the masses and that’s ok.

Chris Harshberger
Chris Harshberger
26 days ago
Reply to  Joe

Unfortunately all with a 90kg weight limit

Veganpotter
Veganpotter
28 days ago

Always wanted one of these. Now that I can afford it, its a no go. No Walton’s will ever get my money.

Greg
Greg
27 days ago

What parts are made where? Their website says the aluminum parts are all machined in house. Does that include the bb shell threads and main pivot notes? Are they then sent overseas for co-molding? Is the fact that they’re co-molded the reason why they’re doing it overseas, they don’t have the capability in the US?
Are the bar and stem made in the US? Are there plans to make other frames or frame sub assemblies overseas?
How do the looming tariffs affect all that?

Veganpotter
Veganpotter
24 days ago
Reply to  Greg

Won’t be long before “in house” means their own overseas factory.

John
John
24 days ago
Reply to  Veganpotter

In house now means that “we have a contract to make them for us but we still have to check some of them ourselves”

Jim
Jim
17 days ago
Reply to  Greg

A part of me hopes they get burned by the tariffs on this, it’s frustrating knowing they moved production overseas when their whole brand was centered around american manufacturing

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