How do you start something from nothing? That’s what Kurt and Martha Forgét did when they created Black Dog Cycle Works (BDCW) out of their garage 16 years ago. Here’s how they built an ADV motorcycle armor and upgrades company, how they test their products, and how they stay consistent in a constantly evolving industry.

 ADVMoto: Let’s talk about how BDCW got started and how things have progressed.

Kurt: We opened for business in 2007 with three products. One of which was a skid plate for the KTM 950 Adventure, our humble beginnings. We eventually brought in other brands to fill in the catalog—products that we tested or already used ourselves. If it wasn’t something we knew was quality, we didn’t carry it. At one point, there were about 400 items on our website from 50 different brands, which got a little too crazy to maintain, so as we expanded, we chose to cut back on other brands.

In the beginning, we were mainly focused on KTM and created the prototype for a friend competing in the Baja 1000 on a KTM 950 Super Enduro just in time for the race. In 2009 we expanded into BMW adventure motorcycles—a big move that transformed the business and took BDCW to the next level.

Martha: There’s a community of small adventure-motorcycle-oriented businesses like Black Dog out there, and we are all big fans of each other. We don’t really think of each other as competitors, which further builds the community and has made it a really fulfilling life for all of us.

We based BDCW on the philosophy that our customer is No. 1, no matter what. We make the best products possible and stand behind them. Kurt and I both find the Internet very impersonal, so we’ve gone the extra mile to make our business a personal experience for our customers. We send personal emails, answer the phone, and go out of the way to make it feel like they’ve walked into our shop. In turn, they get to know who we are and connect with us.

It is also mandatory for us that our products are made in the U.S. That wasn’t a hard decision but an intentional choice. And just as importantly, we wanted local production so the community in which we lived would be supported.

BDCW was born from a love of motorcycles, community, and adventure.

Kurt: It was never an option to take things overseas. Our gear is more expensive, there’s no doubt about it, but the quality is clearly the highest. We’re supporting the American workforce, something we stand for, and based on the feedback we get, it is really important to our customers as well.

ADVMoto: Tell us about the focus on skid plates and footpegs. What are the engineering/design considerations as they relate to off-road riding? And what’s your approach to product testing?

Kurt: It varies on the motorcycle itself, especially when it comes to how vulnerable things are underneath the motorcycle in harsh off-road terrain situations. The skid plate is usually the first place to start and is a key component of the crash system. There are crash bars, radiator guards, etc., but the skid plate is number one. Keep in mind that if you break or put a rock through your motor, you may be in for a long walk home—something that only well-made armor will prevent, and we want our customers to avoid. Given the remote locations we ride, it’s quite a gamble to take a motorcycle with less than stellar protection.

The skid plate is usually the first place to start and is a key component of the crash system.

Martha: When we decide to build upgrades for a new motorcycle, the skid plate is the first design upgrade that Kurt goes after. The motor is the most expensive component, and without substantial armor, it’s not going to hold up off-road.

Kurt: Footpeg designs are all about controlling the bike—like adding “power steering” in that a good design will provide enough leverage to move the bike around much easier with greater safety. It’s also about comfort and the reduction of fatigue because when you’re up on the pegs all day, and you’re on smaller pegs, it’s going to wear you out. Most of our models are also a half-inch lower than stock, which provides a little more legroom as well. Something that tends to be very overlooked by some ADV riders.

Footpeg designs are all about controlling the bike, and the comfort and the reduction of fatigue.

ADVMoto: How do you keep up with new makes and models?

Kurt: We buy the motorcycles, figure out what they need, and then get to work on prototyping, and field-testing the hell out of them until we’re absolutely certain they’re the best they can be. That said, our products are not for everyone, and we know that, but that means our customers know they can count on our gear, that they’re bomb-proof, so they don’t have to worry about breaking something when riding with a BDCW skid plate. We have customers that often buy a skid plate and use it on three different bikes, which is another way of showing the durability of our engineering—it’ll typically outlast multiple motorcycles! Customers say things like, “My bike’s worn out, but my skid plate is still good!”

You won't find a more durable product than a BDCW skid plate.

But one of the difficulties with new or upgraded models is keeping up with the sometimes subtle, sometimes major changes manufacturers introduce.

Martha: When new motorcycles are introduced, or changes are made to existing models, we must be patient in determining their popularity. This is especially true for some models that may introduce elements that affect how the skid plates attach. It can be a challenge to keep up with. There’s always talk about a new bike or model coming out or being released—but we never know whether there is true momentum for it to take off or the number that’ll be sold in North America. However, our goal, even though we ship worldwide, is to stay focused on the U.S. market and what is most relevant here.

Kurt: If, for example, they change their models to the degree our products no longer fit, or require a modified design, then that affects our inventory, R&D, and manufacturing timelines. So often, what matters is how many are actually sold, a number that’s often a lot smaller than the initial hype might indicate.

ADVMoto: As pioneers within the ADV motorcycle world, what are some highlights about working in this industry?

Martha: One of the biggest for us has been the connections and the friends we’ve made through our industry and the community we’ve built as a result. It’s just the most amazing group! We’ve developed lifelong friendships with many customers. It’s been a great ride, and it continues on. It’s a lifestyle.

Kurt: The adventure rider community is a very special group. Everyone gets along and is there to help each other. And the other great thing about it for Martha and me is just the adventures we’ve been on. It’s been incredible.

Grace Schuessler, AKA “The Graceful Renegade,” is an author, vagabond, and adventure motorcycle rider exploring the world on a Honda CB500X. Follow her journey on YouTube, Instagram, or TheGracefulRenegade.com.