Method for forming bicycle frame assembly with integral fastener passage

A method of forming a bicycle structure comprising:

• providing a mold having a first mold half and a second mold half that cooperate to define a cavity that defines a majority of an exterior surface of a hollow finish part when the mold is closed;
• providing an insert that cooperates with at least one of the first mold half and the second mold half and which is positioned in the cavity when the mold is closed, the insert having a curvilinear arm defining a passage curved along a longitudinal axis of the passage that extends through the hollow finish part and is defined by a partition that separates an interior volume of the hollow finish part from the passage and from atmosphere and a bridge that defines an inlet and an outlet of the passage;
• introducing a material into the mold;
• forming the hollow finish part;
• and
• removing the formed hollow finish part from the at least one of the first mold half and the second mold half such that the inlet and outlet are exposed to atmosphere, separated from one another by the bridge, and are flush with the exterior surface of the hollow finish part.