How Do You Box Your Bike For International Flights?

My method is essentially:

  1. Remove the pedals
  2. 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.
  3. Add padding all over the left side of the bike from the crankset to the fork.
  4. Zip-tie the left crank arm to the rear chainstay via the pedal hole in the crank arm.
  5. Remove the seatpost and seat.
  6. Deflate tyres.
  7. Take the front wheel out and remove the rotor.
  8. Wrap lots of padding and cardboard around the fork dropouts.
  9. Drop the bike into the box.
  10. Slot the front wheel down the left side of the box.
  11. 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.
  12. 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).