Packing Your Bike

Materials Needed

A box with maximum dimensions of 60 in. x 32 in. x 8 in.; Allen wrenches; a foot-operated wrench; scissors; adhesive tape; zip ties; a spacer; Styrofoam plumbing sleeves to protect the tubes.

Selecting a Gearbox and Disassembly

The box shown below—which is generally available at bike shops—is smaller than the maximum size accepted by airlines. It requires removing the handlebars, as indicated in step 3.

If you use a box of the largest size—sold at the Maison des cyclistes—all you have to do is turn the handlebars.

If you are traveling on a tandem bike, a Quetzal, or any other non-standard bike, or if you are traveling with a box or a hard-sided bag, please let us know.

Instructions

1 Keep enough air in the tires to prevent them from collapsing under the weight of the bike (± 60 lb).
Position the chain on the largest sprocket and the largest chainring so that the chain is as tight as possible.

2 Mark the seat height and handlebar position.
Remove the seatpost.

3 Remove the handlebars by unscrewing the front plate of the stem, remove the handlebars, and secure them to the top tube. Be careful not to damage the cable housings or the bike computer cable. Rotate the fork 90 degrees. Attach a spacer between the fork legs. Unscrew the pedals. Remember that the thread on the left pedal is reversed, so you must unscrew it clockwise. Once the pedals are removed, place them in a bag and secure them to the frame.

Note: If you have a bike box that is the maximum size, you do not need to remove the handlebars. Simply turn them and rotate the fork 90 degrees.

4 Remove the quick-release skewer from the front wheel. Attach the wheel to the left side of the bike. Slide the bike into the box, making sure to include the saddle, pedals, and any accessories that attach to the frame. Use styrofoam plumbing sleeves to protect the tubes. The box must not contain any loose items (such as a pump or lock) unless they are securely attached to the frame. During handling, loose items can puncture the box, and you risk losing them.

5  Label your bike box: write your contact information on it.

The transport box must contain only the bicycle and its accessories (helmet, lock, water bottle). Airlines reserve the right to open the box at check-in to verify its contents. Any items other than the bicycle and its accessories are prohibited (clothing, food, etc.).

Offprint from Vélo Mag magazine.
Equipment column, Spring 2007. Author: Mathieu Fagnan