My method is essentially:
- Remove the pedals
- Remove the handlebar from the stem and zip-tie it to the frame top tube (everything is padded and separated, of course). I disconnect my front brake lever from my handlebar too as the cable is too short for the bar to sit nicely along the top tube.
- Add padding all over the left side of the bike from the crankset to the fork.
- Zip-tie the left crank arm to the rear chainstay via the pedal hole in the crank arm.
- Remove the seatpost and seat.
- Deflate tyres.
- Take the front wheel out and remove the rotor.
- Wrap lots of padding and cardboard around the fork dropouts.
- Drop the bike into the box.
- Slot the front wheel down the left side of the box.
- Attach the front wheel to the bike using zip-ties (or tape) so that it’s all one package and no parts can be lost.
- My rotor, seatpost, seat, and pedals often go in a separate box along with my panniers (unless I get a 32kg weight allowance, then I put them all in a small box and tape them to my bike – again so that no small pieces can be lost).
