Mechanical Services & Maintenance

Packing and Travel:

Packing Your Bicycle For Shipping

This article will discuss the procedure for packing a bicycle for shipment. This often means taking apart various parts of the bicycle. Although disassembly is an inconvenience for re-assembly, it makes for a well-protected bicycle during transport. The safe transport of the bike relies heavily upon the effort put into packing.

	Begin by marking the position of the saddle and the handlebar with the white-out pen. The picture to the left gives you an idea of how to mark the handlebars so that you can reposition them correctly when you get to your destination. If you mark the seatpost height and handlebar (aerobars too, if applicable…) angle well, all you will need to do is line up the white-out lines when you reassmble and you will be guaranteed that your bike is set to the same riding position as before you packed. It is recommended that you bring a copy of your bike fitting numbers (laminate a copy and leave it in your carry case or have it on a computer flash drive) with you whenever you travel as a back-up.
	Contact airline or other transportation companies for limitations on weight and size. If flying, do not pack air cartridges, solvents, oils, etc. Assume the bike box will be opened and inspected. When dismantling the bike, use care not to lose parts. If there is any doubt where a bolt or odd part is to go upon assembly, tag and note the part. If a component is taken apart, it can be useful to return bolt to bike. Gently snug removed bolts back in place. Assume a loose bolt placed in a thread will rattle out, fall off the bike, and fall out of the box.
Tools Needed: 15mm pedal wrench or 6mm or 8mm hex wrench depending on brand of pedal 4, 5 and 6mm hex wrenches for disassembly Bag for small parts Rags for cleaning Zip ties Packing material and tape to wrap around frame and parts White-out pen to mark saddle and handlebar position Plastic axle spacers for fork and frame
	This is a step-by-step guide to packing your bicycle in a clamshell hard case. The upright hard case designs require less effort and removal of parts so we will focus on the clamshell style. If you would like to make traveling with your bicycle as easy as possible it is worth the extra money to invest in the upright hard case for safety and ease of use.
	We will begin by marking the position of the saddle and the handlebar with the white-out pen. The picture to the left will give you an idea of how to mark the handlebars to reposition them correctly when you get to your destination.
	Taking off the pedals is required for the clamshell boxes but not the upright travel case. Some pedals use a 6mm or 8mm hex wrench from the backside of the crank arm for removal. Most pedals can be taken off with the 15mm pedal wrench. (Do not use a cone wrench for removing the pedals.)
	The easiest way to take the pedals off is to point the crank arm towards the front wheel and align the wrench with the crank arm and push down to remove the pedal. Follow this procedure for both sides and remember that the non-drive side pedal is reverse threaded.
	The easiest way to take the pedals off is to point the crank arm towards the front wheel and align the wrench with the crank arm and push down to remove the pedal. Follow this procedure for both sides and remember that the non-drive side pedal is reverse threaded. Next we want to remove the saddle so we can fit the bicycle in the travel case. The easiest way to do this is by removing the entire seatpost and saddle in one piece. This will make repositioning it much easier. Use your hex wrench to loosen the seatpost clamp to remove the saddle. The last step is to remove the wheels. Start by removing the front wheel first just as you would if you had a flat tire. The rear wheel is next, start by shifting the bicycle to the small chainring in front and the smallest gear in the rear. This will make removal of the wheel easiest. After the wheels have been removed, take the quick release skewer out of each wheel and place it in the bag for small parts. Installing a plastic axle cap is a great idea to keep from damaging your wheels and frame when they are tightly packed in the box. Once you have the wheels out you will want to place the plastic frame spacer in the front and rear dropouts to keep the frame from being compressed during shipping. Let a little air out of the tires, the drop in pressure from the airplane travel will add about 15psi to the tires, so keeping them around 80 psi will be safe.


	Now we need to carefully wrap the frame to keep it from being damaged. Foam pipe insulation works well and can be found at virtually any hardware store. Bubble wrap also works well and can be used to get into smaller places and for wrapping components.
	Putting all the parts into the box can be a challenge but with a good plan everything will fit and travel safely. I always start by placing the wheels in the bottom of the case first. The wheels will be staggered and be sure to place the cassette on the rear wheel on the bottom side. Once the wheels are in, cover them with a layer of foam to protect the frame from sitting directly on them. When you place the frame in the box, be careful not to place any of the frames tubes over the wheel axles as this could damage the frame tubing. Since the handlebars only have a limited range of motion because of the cables holding them close to the frame, you will have to find a safe spot from them so the frame and handlebars fit in the box without being damaged. Once the frame is in the box place the saddle and post, small parts bag, and any other items you want around the frame in the open spots. Be sure all items are protected with bubble wrap to prevent damage. Cover the frame with one more layer or foam and then place the top on the box. The cover will be hard to press down but you can use a little force to get it closed. Once the box is all secure give it a good shake to make sure nothing is loose in the box. Now you are ready to go. Have a safe trip and a great race.