Bike Boxing Tips:

Golden Rule: Preparation and protection NOW keeps your paint job and equipment in great shape later. Also, take your bike owners manual along for reference!

1) Get sturdy non-crushed bicycle box. Remove staples from open top for safety. Cross off ALL addresses and shipping labels currently on box!

2) Remove pedals. CAUTION! Shift the chain onto the top chainwheel to protect your knuckles in the event your wrench slips trying to take the pedals on or off! Note: Turn your (15mm or 9/16") wrench over the top of the pedal axle toward the back of the bike to get the pedals off. Wrap the pedals in heavy paper and bind w/tape or string to keep from floating around in the box. Generally place them on box bottom under the downtube of the bike. To put the pedals back on… Use grease on the threads. Be sure to get the right in the right side, left on the left… then turn the wrench over the top of the pedal axle toward the front of the bike to secure the pedals on.

3) Before removing the seatpost from frame, mark it for the right height. Wrap the post and seat in heavy paper. Place the seat upside down in the bottom of the box to the left side of the rear wheel with the back edge of the seat against the narrow end of the box. Note: put grease in the seat tube, pedal holes and fork column for re-installing the seatpost, pedals and stem when you get to where you are going. There are plastic plugs that can be taped over the seat tube hole to prevent damage to the tube opening… highly recommended. These are from new bike shipping packaging and are available from bike dealers.

4) Shift the derailleur to the small cog on the back wheel. For those with mechanical confidence and the want to keep the dropout from getting bent in the bump and grind of transit… unscrew the rear derailleur from the frame and wrap it in heavy paper, then tape or secure to frame w/string or zip ties. When you reinstall, drop the chain off the front chainwheels and do not have the rear wheel in. This makes it a breeze lining-up the threads into the dropout. Don't mess up the threads of the frame when screwing the derailleur into the dropout!

5) Remove the front wheel from the bike and place a fork wedge (available from bike shops since nearly every new bike is shipped with one) into the fork dropouts to keep the fork from protruding through the bottom of the box. Remove the quick release skewer and screw the end nut onto the shaft until it is firmly on. Tape the skewer to the spokes of the front wheel to know where it is when you get to your destination. Let just a bit of air out of the tires if you will be shipping the bike by air. This will keep the tires from exploding off the rims at altitude. Place cardboard pieces the size of the wheel on each side of the front wheel to protect the frame and to keep the axle from protruding through the box. Place the front wheel on the left side of the bike so that the axle of the wheel is between the 3 tubes of the main frame (this assumes a traditional double diamond [mens] frame). Protect the tubes of the frame with pipe insulation or cardboard to keep the axle from gouging the frame.

6) Before removing the stem/handlebar… CAUTION!!! Remove your bike computer mount from the handlebar to avoid ripping the cord and ruining your computer when you take the stem out of the bike. Tape it to the head tube to keep it from being caught in the spokes when you reassemble the bike. Remove the complete handlebar assembly by loosening the stem bolt (the one on top of the stem). Unscrew the stem bolt three revolutions and the stem should be loose from the fork. If it is not loose, place your wrench back onto the top bolt and strike the wrench with a mallet to dislodge the stem wedge (down inside the fork column). The stem will then be loose to remove. Once removed, tighten the stem bolt a bit to keep it from being lost in transit. Set the handlebars over the top tube of the bike after you have wrapped the top and down tubes with cardboard or pipe insulation. You may have to loosen the stem to handlebar bolt to allow the stem to be rotated to a position that will allow the box to be closed.

7) When putting the bike into the box, turn your fork backward to fit it into the box and to keep it from being easily bent during transit. Note: The best place for your helmet or cycling shoes is the bottom of the box between the crank and the fork. Place a piece of cardboard between those items and the chainwheel to keep them from getting damaged or greasy. Check the handlebar assembly to be sure nothing will protrude through the box in transit. If in doubt, reinforce the box with extra layers of cardboard in those suspect areas.

8) Wrap and secure the tools you will need to reassemble the bike (usually only an allen key and pedal wrench) inside the box. Be sure to have your frame pump, spare tube etc in the box as well.

9) Place a letter inside the box as to who you are, where you are going and how to get in touch with you at your destination in the event the bike is delayed, or damaged.

10) Tape edge to edge the closure. Also, tape the bottom of the box to be sure the bottom can't open during transit.

11) Mark you name, destination address, the phone of where you can be reached at your destination, "UP"arrows & " FRAGILE" largely on the top & side of the box.

12) Insure the bike for the REAL… FULL… RETAIL REPLACEMENT value of everything in the box including accessories and upgrades you have made to the bike. You might be surprised how much it is as it adds up quickly.

13) Relax and know you have done everything practical to be good to the bike. TRAVEL WELL!