Torelli Tires & Tubes

Torelli tire recall: We have learned that the bead of the Torelli Open Tubular Tires, both the Lugano and Verona models, can stretch, allowing the tire to blow off the rim. If you have a Torelli Open Tubular tire on your bike, stop riding it until you have changed the tires. We are offering Torelli TDF tires in a free exchange for the Verona and PGV for the Lugano. Please contact either your dealer or call Torelli toll free at (800)523-6604.

Torelli Extra-Lite tubes for road and ATB
Torelli Verona Open Tubular tires
Tread patterns of the Verona, TDF, and PGV tires, from left.

I've written an essay describing the different types of high-performance bicycle tires and how to choose the right one for you.

There is an essay at the end of this page you might find interesting: how Torelli tubes are made.

Torelli Extra-Lite Inner tubes

Mountain Bike Action magazine 4-Star rated product.

Torelli Extra-Lite ATB tubes were also cited by Mountain Bike Action as one of the ten hot things you should buy!

Torelli Extra-lite tubes are the most cost-effective way to improve the performance of a bicycle.

Torelli tubes enhance performance two ways. First, the rotating weight is substantially reduced. Given that the energy needed to accelerate the rotating mass of the wheels is greater than the energy needed to accelerate any other part of the bike, this weight saving is important.

The other energy savings is gained by flexing less inner tube mass. The tire and tube are deformed as they roll over the ground. This deformation takes energy. By reducing the thickness of the tube, the energy needed to roll the wheel over the ground is reduced. More of the rider's energy is used to propel the bike forward at a higher speed.

Torelli tubes are butyl rubber. Extensive investigation and tests convinced us that the reliability and repairability coupled with the low cost made butyl the only choice. We went to France for our tubes because the density of the butyl available there allowed us to make the tube only .4mm thick and have it still retain air.

Torelli Extra-lite road tube, 80 grams, 35mm threaded presta valve. Wall of the tube is .9mm thick. 700C x 18-20-23-25, or 650C x 18-20-23. Suggested retail, $5.99

With 48 mm threaded valve stem, Suggested retail $6.99.

Torelli Super-lite road tube, 60 grams, 35 mm threaded presta valve. Wall of the tube is .6mm thick. 700c x 18-23. Also available with 48 mm threaded presta valve stem. Suggested retail, $9.95

Torelli Extra-lite ATB tube, presta (135 grams) valve. 26" x 1.85-2.125. Suggested retail, $5.99

Torelli High Performance Tires

For more information on the different types of tires, their applications and how to choose the best one for you, here's an essay that explains tire construction and perfomance.

There are two basic kind of Torelli tires, Open Tubulars and Clinchers. To really understand the differences, please click on the the link above

On the left: Torelli Verona tread closeup.

Above: Torelli Verona (mounted on a Triumph clincher rim) sidewall detail.

Torelli "Verona" Open Tubular. The Verona Open Tubular tire is made with a 240 TPI casing that gives a superb road feel and unrivaled perfomance at this price. If you see one at a shop, take it in your hand and crush it. You will be surpised at how supple the casing is. This supple casing allows the tire to immediately adapt to changes in the road surface.

To eliminate friction and stress between the casing and the tread, the tread is hand-glued to the inflated casing. This hand made process is called "cold treating". This is how the most expensive tires used by the most demanding professionals are made. The result is the equivalent of radial tires for your bike.

Weight: 220 grams
Color: black
Casing material: Polyester
Size: 700 x 23
Bead: folding Aramid
Pressure rating: 100 - 130 psi (Run it at 100 - 110 and your bike will ride much better)

Suggested retail price: $29.95

Torelli Pneu Grande Vitesse (PGV). Many riders prefer a traditional clincher with its thicker vulcanized tread. For those who find the need for durability very important we offer our PGV and TDF (below) tires. We have worked to make the casings supple for superior respose to changes in the road surface. Our PGV is the state-of-the-art clincher using a 120 tpi woven nylon fabric casing and a natural rubber-butyl blended tread. The tread uses Torelli's grippy, soft formulation to give the bike maximum corning power.

Weight: 210 grams
Color: black with grey
Size: 700 x 23
Bead: folding Kevlar
Pressure rating: 115 psi

Suggested Retail: $49.95

Above, the Torelli Tour de France clincher tire.
Tread patterns of the TDF (left) and PGV (right) tires.

Torelli Tour de France (TDF). Looking for a good training tire with a supple casing and soft tread that wears well? Then the TDF is your tire. The TDF has a 60 TPI woven nylon casing and a sticky tread. Don't get training tires that beat you and your bike. We're supposed to be having fun.

Weight: 230 grams
Color: Black
Size: 700 x 23
Bead: Folding Kevlar
Pressure rating 100 psi

Suggested Retail: $39.95

How Torelli Extra-Lite tubes are made

The factory receives the various raw materials, butyl rubber, natural rubber, the different chemicals added for vulcanization, as well as the valve stems, from other suppliers.

Each item the factory produces: tubes, tire treads, casing, etc., has its own recipe. The first step is to make the right mix of raw materials for the tubes. The workman puts big blocks of rubber on a giant scale until the quantities are just right. He has several large knives kept in a heater to slice off pieces of rubber to add to or subtract from the mix.

The batch is mixed by being forced between huge smooth rollers, round and round until the desired consistency is achieved. Then it is extruded in a wide, flat belt onto a pallet that is numbered and stored for 24 hours. During that time, a sample is sent to an on-site laboratory to make sure that the recipe has been precisely followed. If there has been an error, the batch is useless and must be thrown away.

The next day the rubber is transported to an extruding machine. The rubber, which is still malleable like a stiff clay, is fed into an extruder that squirts out a long continuous tube the diameter of the final inner tube. As it is being extruded, talc is sprayed in the interior of the tube so that the inside walls of the tube do not stick together. Passing out of the extruder, it enters a water bath, cooling it so that it isn't too soft to work with. A rolling stamp puts on the 'Torelli' and the tube size that you see in silver ink on the tube itself. Then, a drill precisely cuts a 5mm hole in the tube every yard or so. A little vacuum holds the top of the flattened tube away from the bottom so the drill does not go all the way through the other side of the tube.

A feeder from a large bin brings the valve stem to the hole in the tube where it is heat-bonded. The valve stem comes with the rubber reinforcing base already attached. The 53 mm long valve stems used on tubes for aero wheels must be placed by hand, as the automatic feeder will not accept the long valves. A cutter cuts the tube to the correct length and the outside of the tube is given a coating of talc. The ends are placed together by hand and heat sealed together to make an inner tube.

The tubes are stacked on racks of 1,000 for 'cooking' or more correctly, vulcanization. The tube so far, is made of a malleable, soft rubber that has no strength. Upon being 'cooked' the tube becomes a strong, reliable racing part. After cooling, the tubes are boxed and shipped to Torelli in California, ready to hot-rod a bike. Return to top of page.


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