8 Hacks For Packing A Bike Box | Useful Tips For Travelling With Your Bike

Travelling with your road bike doesn't have to be scary. Ollie has some great hacks that will keep your bike safe and sound as well as easier to rebuild once you've unpacked it.
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📹 How To Pack A Bike Box | gcn.eu/BikeBox
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[@gcntech]

If you've got any useful hacks for packing a bike box, share them in the comments below 👇

[@nejcprevalnik9534]

Great video it was really useful

[@paulhatcher1490]

Great Video. I'd also say put some wooden or plastic packing spacers in between the front and rear dropouts. This should then stop any crush forces from breaking your frame. A frame is designed to take loads in certain directions. Without wheels in it can be very vulnerable to sideways crush forces. Airport baggage handlers seem to enjoy giving bike boxes "special" attention :0

[@2001MBKBooster]

If you purchase a bike online and it's shipped to you for assembly, take plenty of pictures as of how they managed to pack it and place into the box. You'll know where to attach padding and protective wrap, place the handlebars, and see where the wheels rest next to the frame. Upload the photos to a cloud account like Google Photos and you'll always be able to use them as references.

[@mungolikescandy3270]

if you have thrown away all the packaging from your bike and your local bike shop can't help out, there's always foam pipe lagging available in various sizes

[@oraszuletik]

Put your sensors into deep sleep or remove batteries.

[@stevecarpenter7462]

A couple of extra points. I must have departed from the USA thirty or so times in the last few years with my bike box. EVERY time, the TSA have opened my box (they leave a leaflet in the box to inform you they’ve been there). My box, a Velovault, has a fixed anti crush pole, so no problem, (except sometimes the Velcro holding the bike has not been properly refitted). I have heard horror stories about boxes with removeable anti crush poles not being properly replaced by the TSA, with resulting damage to wheels and frame. Consider this if buying a new box! Cardboard and soft boxes may be ok. (Light and cheap)The loaders MAY possibly treat them with care. For peace of mind, though, a solid box is better IMHO. A Richey Torq key is a great asset when reassembling the bike. Fit extra double sided Velcro points in the box (M4 bolts and washers) to secure extra bits and pieces such as tool roll, compact track pump shoes etc. etc. Some security staff consider pumped up tyres to be compressed gas, but I still leave some air in to protect the rims. Many security staff will seek out and confiscate Co2 cylinders, despite IATA allowing them, and spares, on life jackets! Just sayin’... Fit quick links so chain removal is easy. A dirty chain in a freezer bag strapped securely won’t spread grime everywhere! A decent track pump propped between two chair backs can act as a useful stand for tuning the gears, which you may well need to do after refitting the rear mech. Don’t rush the reassembly, and enjoy the trip!

[@RickyWijaya86]

OMG, yes. This is exactly what happened to me. TSA would have no idea how to put the things back together, so your best bet would be to buy travel insurance just in case. Also I've heard horror stories where they would scan the luggage and see that there's wiring and battery (i.e. Di2 seat post battery) and pull apart your wires. Frustrating, but that's the US for you.

[@stevecarpenter7462]

Hi Ricky. That’s a good point about wiring and batteries. Much as I love my Di2 and disc brakes, I feel mechanical and rim brakes are easier to travel with. Imagine arriving somewhere with a badly bent rotor. Bad start to the trip. In fairness, lithium batteries contain a lot of energy and are difficult if not impossible to deal with if they run away and catch fire whilst in the hold. I believe airlines would be justified in requiring all lithium batteries to be carried in hand luggage. The only way to deal with a lithium battery fire is to immerse it in water, an option not available in the hold. Also might stop the TSA guy from ripping things apart. 😫Fly safe. 😃🛬🚴🏻‍♂️🛫

[@KevinSteeleisme]

If you ever do another version of this, I'd highly encourage throwing an AirTag into your bag. You can watch it move through the airport(s) with you after you hand it off at the luggage drop-off. Maybe not a packing hack - but certainly a sense of security hack :-)

[@pedroschlude2942]

Instead of a Cardboard box with a bike manufacturers logo on it you can also use the box of a really expensive flatscreen TV and hope that the people at the airport will care a bit more for it. I think this tip was given by your very own Jon Cannings

[@shaunhoulahan4080]

Removing the rear derailleur hanger is a great tip. My first trip away I didn’t do this and I had skipping gears in my first and only World AG championship event. Taking a spare hanger and a spare headset Bolt is a good idea too.

[@robincogghe8801]

*me, never even thinking about traveling with my bike* *sees GCN video about traveling with my bike* me: I must watch this...

[@mcorbett01]

What a very useful video. Some great tips. Many thanks!

[@Muppetkeeper]

I have a Bike Box Alan, with a 56cm frame and my saddle set for 180cm, I don’t even need to take the seat post out, it fits great. The box is almost indestructible too.

[@davidhutchinson5122]

Paul - can you recall the dimensions of the bike box? Is it cardboard?

[@SoyCyclist]

perfect timing for my trip to Arizona! cheers GCN!

[@stuartdryer1352]

Timely for me. Thank you.

[@Hintonbro.]

The protective plastic discs bike manufacturers attach to disc brake rotors are super useful to get from your local bike shop in order to help guard against bent rotors while traveling

[@frazergoodwin4945]

Pack your pedals, shoes, riding kit and saddle in your hand luggage. That way if for some reason your bike doesn't make it to the destination (e.g. plane hold was full so the airline didn't load it on your flight - and will send it "later") this means you'll still have the ability to hire a bike at your destination and ride any event you were planning to do with all your own contact points. (Just don't forget to pack the bag with your pedals and tools in your hand luggage so you have to go our and buy an new pair of pedals when you arrive - yes, I have made that stupid mistake!)

[@stevecarpenter7462]

Good suggestions, but be very careful about what tools you put in you hand luggage. I doubt you’ll be allowed a multitool or even a pedal spanner if they are detected by security...

[@frazergoodwin4945]

Multi-tool has been OK for me in the past - as long as there are no sharp blades or points on it - so just Alan keys... but you're right about larger tools.

[@stevecarpenter7462]

Hi Frazer, Good to hear you’ve been ok with your multitool. The problem is lack of consistency with security staff, one may take a pragmatic approach, the next will be a complete idiot. They were confiscating tea spoons off us a few years ago! They argued it could be used as a tool. You really couldn’t make it up! 😫

[@frazergoodwin4945]

@@stevecarpenter7462 I know what you mean - I fly often to Sweden and they are a bunch of absolute numpties about baby buggies of all things - which is bizarre as the rest of Sweden is really family friendly.

[@stevecarpenter7462]

Hi Frazer, Absolutely. I think Heathrow is ok with baby buggies, although they will need to be scanned, but it’s the inconsistency I find so infuriating! I think things have improved slightly in the last 18 months, but it shouldn’t depend on the whim of individual security staff.

[@Majikplayer]

I had some issues previously when I removed the stem from the steerer. But getting the handlebar/hood angle right afterward can be a pain. So I opted to buy a spare stem for cheap to clamp on the steerer for travel.

[@florianmatz1885]

I’ve cut out some foam for the delicate parts of the bike and also in a wheel-shaped form to pad up the wheels in my Scicon Aerocomfort. Great bag, but a bit of additional protection makes you a lot calmer ...

[@stevecarpenter7462]

Thanks Ollie. Nice video. I’m lucky enough to fly with my bike to a great Longhaul destination at least once a month, and I can completely agree with all those tips except the riding with only 3 out of 4 stem plate bolts. I found one of my bolts stripped on assembly in Vegas. As I needed to be on the road very early next morning, I thought 3 out of 4 bolts would work ok. I got halfway up the Red Rocks Loop, and the bar started to rotate. The 20k ride to the bike shop whilst pulling back on the bars was ‘orrible! Of course, no problem with those sexy aero bars, but be aware if you have a more conventional round bar.

[@MP-wb5yd]

Love the tip about the clothes, never thought about that 👍👍

[@krishnansrinivasan830]

Awesome & Thanks :)

[@yarapereira6752]

Works better than expected

[@madpeddler8263]

I always remove the handlebars and stem from the fork and use another short stem to secure the fork to the headset. A short stem can be turned around without making contact with the top tube even when slamming the headset. Also use plastic braces on the fork and rear dropouts, these can usually be acquired at your LBS. I remove the bottle cages and wrap these with the bottle in soft foam. The space inside the triangle of the frame becomes a good spot to put the helmet.

[@jamesporter5630]

Put old hubs in rear stays and fork. (If you don’t have old hubs...ask your LBS.)

[@Bluesman2509]

Thanks Ollie sounds like a plan for Mallorca!

[@Hintonbro.]

When using a cardboard box, reinforce the handle cut-outs with duct tape - and use plenty. The luggage handlers are not gentle and the cardboard will tear there first.

[@robbybobbyhobbies]

BikeBoxAlan is a great box and protects the bike perfectly, but ... the x-ray machines at Heathrow T2 rejected mine and I had an extra hour of stress as they ushered me and the box to a separate room for a detailed search (just the bike box , not me). Also, always remove your disc brake rotors. First flight to Canada (with a Polaris box), both rotors were bent beyond repair, which added a chunk to the cost of the holiday.

[@michaelfeinstein7240]

Bear in mind a new mech hanger may not be aligned when it's new. Use a tool like a Park DAG derailleur hanger alignment tool to set up the hanger before you leave home. A shop on the other end could do it as well, but it's nice to have it ready to ride just in case so you won't miss any ride time.

[@LUCYDIAMONDBOXER1]

Travel tip: Enquire with airline regarding taking bike box as luggage allowance (23kg generally) which saves you spending £30 - 60 each way. BA allow this

[@stevecarpenter7462]

Absolutely true! And they have a generous cabin baggage allowance. A 22 inch wheelie, and a small computer bag. I mean, how many underpants does a chap need? 😃

[@deanstevens1451]

You can remove the handlebar with stem if you have a locking collar on your fork. The locking collar acts as one of your spacers and prevents the fork from falling out. The locking collar needs to be the top spacer. Santana does this in their travel tandems.

[@shaun2381]

If taking a carbon bike, always take a small torque wrench and carbon paste, especially if removing a carbon seatpost!

[@Steve-jo3cl]

Great tips Oli, here in Australia though we aren’t allowed supposedly to fly with a lithium ion battery ! Isn’t that the type of battery DI2 uses ?? But funnily enough the same airlines that don’t allow lithium ion batteries actually have lithium ion batteries that back up the avionics system on the plane! What a contradiction !!!

[@bastogne315]

Nice..in the event of a front, side or rear collision what happens?

[@andrewbackhouse5828]

Besides the usual multi tool, I take a small torque wrench and some carbon paste.

[@Clashing0N]

On a bike with mechanical gearing, how do you secure the rear derailleur after taking it off the hanger?

[@keatonjohnson1130]

Hi gcn , I'm going abroad with my bike for the first time and was just wondering if removing the chain completely would be a good idea then it's not dangling around possibly chipping my frame have any of done this before ? Yes I have quick link

[@douglasmacrae6292]

In 30 to 40 international long haul flights, I have only suffered damage once - a buckled wheel while using an EVOC bag. The problem was caused by the frame to which the bike is clamped holding everything rigidly in place, and I have stopped using it, mounting the forks into the padded “road bike adaptor” instead. I use tape and cable ties to hang components to the bike so that they have some room to move. This includes the rear derailleur which I remove, and leave suspended on cable ties between the rear chainstays, cable still attached. If you do this it’s important that the rear derailleur is in the small sprocket position before reattaching it, or the cable is too tight. I use paraffin lube, but if conventional lube is used, latex gloves are helpful. It’s important to use anti-seize grease on the pedal threads and not to over tighten them, or they can be a cow to get off when you pack to return home.

[@petinka721]

Ollie made it again!

[@gabbechico8471]

and if have a S-wors Venge 2019 for exampel were u cant take of the handelbars?

[@georgecumming760]

Silly or unusual question but what are the logistics with arriving in, say Madrid, cycling to say, Naples and you have a box/special box and extra stuff? Is it as simple as DHL your stuff to the final waypoint/departure point? Has anyone experienced this?

[@markusmencke8059]

Tape the cables to the protecting insulation, not the frame. No glue residue on the frame - and no scratches when you try to get the tape off the frame... And take a torque wrench with you!

[@desmondlam8072]

There are many useful tips in the video. However, I would disagree with removing the faceplate to take out the dropbar, instead of the stem altogether. During the assembly, you will need to centre the bar, tilt to correct angle (of course you can paste stickers beforehand) and torque it evenly, and reinstall the computer mount. There is quite alot of work. I would suggest that you just put many spacers (buy some used metal ones to save cost) to fill the gap and lock with stem cap. This method saves some steps and avoid the slightest risk of changing the bike fit due to the tilt of the dropbar. Imagine you will also need to do the same thing on the return trip.

[@ronngren655]

Lots of great money saving tips, but a 10p Waitrose bag!

[@davex5424]

What about packing when you have fenders and racks?

[@germanangarita2035]

Which bike box recomend me for a TT bike? I am between bike box Alan or Thule? Thanks in advance and sorry about inconvinience.

[@austinpangcog8240]

What about carrying tools on the plane with your luggage or bike box, what are some tools that are ok to take and not ok. Is it easier to take tools with you or buy some from the local bike shop in whichever state or country your flying to?

[@Cesttoileusername]

Can we please get a refresher on how this all works in the era of bikes with fully integrated cables?

[@franbridges7615]

How do you secure wheels with through axle?

[@georgehugh3455]

Great tips by Ollie, PhD, Caveman Penmanship (Afraid to see how he eats!...)

[@truskawkatrusk1254]

Best advice: buy thule With its integrated assembly holders. Great stuff

[@stevecarpenter7462]

Very nice, but pretty heavy too...

[@ighfirlee]

Hi GCN, can you show. how to pack a dusc bike with fully integrated bars like the Factor One Disc? The challenge is the hydraulic cable length limitation when taking out the bars.

[@David-vb8tg]

tumbleweed

[@mattswindells4893]

How do you know its going in a Transit? might be a Merc Sprinter. You just can't tell.

[@umzzz1999]

Did you guys get some new cameras or lighting gear? Seems like the quality of this video went noticeably up!

[@cwickjable]

I agree! I noticed that within the first 4 seconds... Literally lol

[@MrSparkyAprilia]

How about how to pack a bike with integrated cables? I'm taking delivery of my 2019 madone disc in March and heading to Mallorca in May and unsure how easy it will be to fit into a bike box!

[@ighfirlee]

Yeah, interested to know this too. The hydraulic cable length will be a challenge. Or use a bikebag like Elite Borson

[@roldsvideocollection7744]

But how about specialized roubaix 2022 di2. It has battery inside the seatpost😢 i dont know if i can remove it😢

[@Uppercottage2]

OMG.......the ‘water bottle hack’ is pure genius!........

[@jinngeechia9715]

I use an Elite Super Byasi tool bidon. The largest one they have. Doubles as a tool bidon when I get there if I decided not to use a saddle bag.

[@pauljohnson5553]

but what about all the bikes with integrated bar/stems?

[@martinsutoob]

On a di2 bike with seatpost battery take care when removing from seat tube that it doesn't suddenly jump out and yank the cable off the battery. I did that and damaged the connector. Also write your name and mobile number on the *outside* of the box (with international access code of course). Then you'll know you're just a phone call away from being reunited with your precious.

[@Bad_Science_Channel]

martinsutoob good point on yanking the cable! I’ve seen people do that!

[@user-yy8ng4zy6b]

Reinforce inside if a cardboard box where axles can rub and even punch through. , Just by taping on more cardboard

[@mrsverdin10]

What is the handlebar size?

[@ChromeStrand]

Thanks for the great tips! I am thinking to travel abroad in the near future, and i have one concern about my Vision metron 5D which is integrated Stem/handlebar. I may have to remove it, is there a way to keep the fork from moving around? like clamp or something. Thanks!

[@drfreeheel]

ChromeStrand if you have to take the stem off, you can make a collar out of cardboard and tape that you put in its place and secure with the stem cap. This will keep the headset together better than nothing at all.

[@ChromeStrand]

Sounds really good! I will try that, and maybe add a couple of rubberband above the cardboard to keep it in place :D Thanks for the tip!

[@bobski36]

Topeak makes a 'temporary' stem spacer for travel. You put it in place of the stem and then tighten it down with your existing stem cap.

[@nemalyprakash]

I bought the same box only to realize i can't fix my thru axle wheels as the holes are made for QR axle only. Any tips on how i can fix the wheels. Any adaptor available for both rear and front.

[@hillhurst_production]

Just buy some cheap QR levers. work fine.

[@eriktabor6478]

Instead of fishing the wire out the seat post with a spoke or some made tool, why not flip the bike upside down and shake? It’s free and not too heavy.

[@wilfdarr]

Roadies aren't known for arm strength 😉

[@bobwalsh57]

Good video, but I was hoping you showed how to pack the wheels. Cheers.

[@jinngeechia9715]

I put the wheels into wheel bags and have both flank the rear derailleur or derailleur hanger should I remove it, to cushion it from any impact.

[@Pinguinausquetscher]

I always pack my bike in a carton, use a lot of tape and hope that nothing breaks. :D

[@williamschultz8198]

Haven't seen Ollie in a while...has he been on Holiday?

[@nicks6871]

tighten stem bolts... with a torque wrench.

[@David-vb8tg]

nah

[@hughbriz]

I have a small cover for the chain and rear mech which keeps stuff near it clean - also v useful for moving the bike in the car. When removing the seat post you may need to also take out and store any integral clamp as otherwise it might get lost! Agree about spacers or axles for dropouts. I don't have discussed brakes but my friends have had a lot of trouble with rotors getting bent. Pipe insulation and electrical tape are your friends. If putting the bike upside down into a bag, tape protective insulation to the clamp area that will be on the bottom - and make sure the brake cable isn't going to be crushed! Some of these things might have happened to me..

[@shuycg]

Guys, I basically only travel with my wife and kids. So that means I already have truck full of luggage. How do I add a bike travel case to that? How do dads/moms take their bike in their family travels? How to get to the airports and to the hotels?

[@datadps9142]

Read the baggage weight limit for your flight. An alan bike box is 13kg and a 7kg bike will be just 20kg, you won't be able to add anything else in your box if the that'sthe limit. Pay attention if you don't want to pay extra cash.

[@garyguillemette5989]

#TorqueBack Question: Carbon rails on saddles are not round, and some seat post clamps do not conform to oval shaped carbon rails perfectly. So what can you do without having to change the seat post? I have a Canyon Aeroad, so I would not be able to change out the seat post very easily.

[@cezarymikolajewski]

How to pack a bike with an integrated handlebars?

[@richaw6689]

How were you holding that pen sir? Good tips, even if your pen skills are rather cave-man!

[@stevewindisch2882]

Avoid insane bike-specific airline fees by using something that doesn't scream "There's a bike in here!" (I like my Pika bag). If the desk agent asks what's in there, tell them it's an art project (hard to prove something isn't art). I've flown dozens of times and never paid more than standard luggage fees despite the bag technically being 20 linear inches oversize

[@saki2789]

ORBEA made at Vitoria (Spain).

[@gavinmurray2848]

I can’t recommend Buxumbox highly enough I have a TOURMALET BIKE BOX , I use it for my 56 frame Izalco Max & canyon Ultimate the have adaptor kit for thru axel & quick release secured well and to the box fittings , not cheap but one box for all occasions .

[@charlietompkins8576]

Ollie does have a strange tape obsession... "you can use tape for this...or this...or this! I also recommend you use tape for this..."!

[@Bad_Science_Channel]

Charlie Tompkins so many applications!!

[@Katykat7777777]

I’m enjoying the bike so far kzbin.infoUgkxMesz3KOGEmwmvyKQfLfrRSUXLFzfVHZA My only real complaints are the brakes and the pedals. I feel like a bike designed for bigger people should have much larger pedals and more heavy duty brakes. I’ve only gotten two really good rides out of it, minimal downhill action, and the brakes feel like they’re already going out. A larger person has more momentum, so I think this wasn’t thought through very well. Also, I wear size 13-14 wide shoes. My feet cramp up on these pedals that are clearly made for smaller feet. Since I’m not a pro rider (and I don’t think many are who purchase this bike) I don’t think that the straps on the pedal are necessary at all. None of this takes away from the enjoyment I get from riding, however. I’ll just head to a bike shop to improve on a few things.

[@JohnBatty]

After watching this video and reading the comments below, I'm never going to pack my bike. I'll hire locally at destination.

[@stevewilts]

Wear your helmet on the flight. Never know when turbulence may occur! Saves space in luggage too...

[@srpskihayk]

Aren’t rechargeables like power pedals, electronic shifting batteries, and such forbidden in cargo hold?

[@trick700]

Yah, thru axles are a problem ‘cos bike box is designed to hold QR’s. What is the hack without damaging anything?

[@newttella1043]

Time to upgrade the bike box.

[@stevecarpenter7462]

Fit three or four double sided Velcro straps per wheel. I fix them with M4 bolts and nuts, with a large washer. Velovault comes with both options...

[@BlueboosuphuSKI]

dat hand writing

[@neisseriagonorrhoeae]

Anyone who has ever been in the military knows that black electrical tape is the answer to all of life's problems

[@yurimow]

Don't want to be negative, BUT usually renting a bike at the place you go to is cheaper than flying yours there and unless you own a carbon di2 spaceship, 9 times out of 10 you end up with a better bike than the one you left at home.

[@barrygraham6795]

Unless you're going for 6 or 7 weeks of course

[@trick700]

What to do with discs, on or off?

[@newttella1043]

Depends on what case you are using and how careful you pack your wheels. Shimano center lock discs are easy to remove. I would consider changing wheels for this feature if I flew a lot with my bike. Disc seem to get bent when using my EVOC bag. Never had an issue with the hard cases or a cardboard box though. Cardboard boxes however are hard to move around in airports and you have go find a cart rental, or get scammed by those airport porters.

[@trick700]

Newt Tella thanks, cardboard boxes are a risky solution in case they are put on their side below a pile of baggage. Bikes are may be delivered in boxes to bike shop in collapsed state but also with oodles of professional packaging protecting them. Hard boxes are safe way and I can vouch for the Bike Box Alan featured in this vlog

[@newttella1043]

@@trick700 I agree that hard cases are the very best. But here in North America, airlines have a 50 pounds weight limit before we get dinged another $50 to $75 for being overweight. The last hard case I used was 32 pounds so that only leaves 18 pounds for your bike. I mostly fly with my mountain bike, 25 pounds :(

[@trick700]

Newt Tella the Bike Box Alan has tare weight of 25lbs (11.3kg). Might help you

[@newttella1043]

@@trick700 Good to know!

[@realhass]

top tip, just get broomy its much easier to travel with.

[@David-vb8tg]

more like bottom tip

[@ketle369]

Instead of asking the local bike shop for a spoke, I’ll just ask them to reassemble the bike for me or fish out the cable.

[@jamesrosca8408]

We usually dont remove the stem from the frame. And the whole cockpit is tied to the frame. Sometimes if we just remove the cockpit from the stem. My friend broke the screw before Our race while he was correcting the angle of the base bar. He overtorque the stem Bolt and broke it. Had to find a screw good thing he Foundation One before the race

[@joeinglesfield7446]

Your local bike shop, ahh a bit like a charity shop but you don't even have to pay for anything

[@petermorris3060]

Glitch in The Matrix?

[@billy3fist]

Do you always write like that?

[@mikedio]

You forgot the wheels.

[@Jack42Frost]

I always leave my mudguards at home.

[@woozertoo]

Foist.

[@okantichrist]

woozer Are you from across the water 😂

[@jayj.manalo2271]

I got charged 5 bucks for a box from LBS......

[@erictofflemire8200]

Wow, what kind of BS is that? It saves them from having to break it down and take to a recycle bin. My LBS is always happy to get rid of them.

[@pedallinraw]

Cardboard box every time 🙂👌🏻

[@molfar9049]

now try it with Madone or Venge!

[@PhilipClare]

Waitrose bags, clearly getting paid too much!!

[@Darthshearer]

Why is everything a 'hack' now in your videos?

[@realalbertan]

Email address on the outside of the box

[@RussThorne1]

Who taught Ollie how to hold a magic marker?

[@Ultegra10SPD]

Return Journey home, put your dirty filthy nasty clothes inside out inside ur bike box. Good TSA Agent Repellent. Credit to Seth's Bike Hacks. -U10

[@dh7314]

Can't afford to swan around the world pissing about on my bike, I have family holidays to pay for.

[@fullofshit3056]

David Harper unlucky Dave

[@Walking_Death]

yeah, but some of us can.