How To Pack A Cardboard Bike Box

Travelling with your bike? Save money by using a cardboard bike box.
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Bike bags and bike boxes offer great protection for your pride and joy, but in this video Daniel Lloyd takes you through another, cheaper option.
Cardboard bike boxes are often thrown out by bike shops, and with some extra padding, they can make great improvised bike boxes.
Got anything to add? Leave your tips in the comments below.
Music: Sarah Williams White - Hope and Lust: gcn.eu/1roOxct
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Music licensed by Cue Songs

[@michaelalquist7497]

Good video but I've traveled exclusively with ONLY a bike box, so here are several things to remember:. 1) Place a wheel on each side of the bike frame (not both sides as shown). This will even the distribution of weight and allow for even better protection of the frame above what he's done there. Buy two small rubber balls (like the ones you'd buy for your dog) slice a few slots and slide over the outside facing hub center and tape, this way they won't penetrate the box. With that said, I've never used a box that I couldn't leave the rear wheel on but if you're unlucky enough to not get a box that is sized appropriately the method shown in the video will work. 2) Buy two tennis balls, cut slices in both and press over the end of each front fork prior to sizing and cutting the pipe wrap over forks. This will keep the forks from penetrating through the cardboard. 3) It appears the box was either too small or he didn't push the seat post all the way down into the seat stay. By pushing the seat post down, you can place your bike helmet (for those smart enough to wear and own one!) over the seat, this provides a super strong push out from the frame AND the helmet will actually fit perfectly in the box without bulging. Tape the helmet to the frame (more on why in #5 4) Tape the handlebars securely (he did not do that), otherwise they'll flail around and yes.. they can and will scratch the frame somehow! 5) If you are shipping this with you in the USA OR if it is going to the USA, forget about putting a lot of tape to seal as the TSA WILL open the box for inspection and reseal with TSA labeled tape anyway.. so don't get to elaborate, you'll only be disappointed when you get to your destination and find your pretty box has been violated! Remember to secure those wheels with tape to the frame in such a way (he did not do this in the video) 6) He is correct - do not include items like the pedals.SPD's or other small items unless you want them to fall out somehow 7) If you are returning (round trip) be sure to use a marker to identify on the pipe wraps where they go and take pictures with your smartphone once you're done so you remember exactly how you did it the first time. And NEVER leave water in your water bottles as the TSA has a habit of throwing them away if they do upon opening and inspection AND your bike might be tagged for further inspection and you won't see it on the other end of your trip..! Take it from me! 8) Take everything of value out of the seat post bag or it could be confiscated. I had a friend who left a bike tool and since it had a knife blade, it wasn't there when we got to the island!, and 9) Deflate your tires.. mandatory by the airlines, but not all inspections catch this. if you do not deflate your tire will most likely explode in the box while at high altitude.

[@mononomous0629]

I need a llink to your video asap!

[@omalinsky]

what is wrong with screwing the pedals into the cranks the opposite way rather than removing from the bike and carrying separately?

[@georgekoukouris2347]

Thanks so much this is great stuff

[@justinkrann7406]

Do you think its okay I squeeze in my guitar and a misc tools too? It fits I already check, quite nicely too. Will the airline care?

[@ipulledthepin7179]

If you have a cardboard box big enough to leave rear wheel on would you still remove the rear mech and secure within the frame?

[@matprlz]

Perfect timing for my 4000km of japan later this month!! Thanks GCN

[@raptuspl]

I got a 61cm xl frame and keep the rear wheel and derailleur (set the the easy gear) on. The handlebar is tied and secured to the fork. Also a good idea to put all the clothes in. In the video you put the bike in the box without securing the chainrings which might get damaged during the transport. I keep the chain on the big dog to avoid the sharp teeth going through the protective layer. So far no problems at all :)

[@ElSachinoo]

used the method in this video flying back from a tour and about to use it a second time! cheers gcn.

[@bittersweethood]

very useful video!! thank you Dan, you make it looks like it is so easy

[@dudeonbike800]

If you want to see how a properly-boxed bicycle looks like, just visit your local bike shop and pull a new one out of its box! Now this may not be 100% perfect for international travel, but it will give you a good idea. This video does bike boxing an injustice. It's obvious to me that this person hasn't boxed very many bikes in his life - or if he has, he's been doing it wrong a lot! 1) Leave the rear wheel in! The wheels reinforce the frame. If you could leave the front in, you would. But you can't. But the back stays in. It prevents the rear triangle from being crushed. Trust me, it probably will. Sure, SOME bike makers ship bikes without wheels, but these are the minority (and if they do, they make sure to protect the frame). But in a standard bike box that 99% of you will use, you need to leave the rear wheel in. 2) Fork brace. The fork will also get crushed and/or it will poke through the bottom of the box without a brace. The ideal brace would be a spare front hub, or axle and QR setup. This is ideal because it won't be dislodged. If you use a typical brace, tape it so it cannot fall out. 3) Box all spare parts. Or attach to bike. 4) Axle ends need to be covered! That front wheel will suffer two bad fates. First, one side of the axle will pop through the box side and then tear it open, and second, the other side will mar the crap out of the down tube. 5) Don't deflate the tires. Standard air pressure is 14 psi. So if you flew in outer space and the cargo hold wasn't pressurized (it is), your tires would only increase 14 psi. No big deal at all. But if you're super scared of tire pressure, then let some out if it makes you feel better. If the airline says let out the air, tell them to learn some fucking physics!!! 6) Rain & water dissolve cardboard. A friend of mine flew cross country with his race bike and when he arrived, the airline handed him his frame and rear wheel. "Where's the box it was in? What box? Where's my front wheel and other parts? What parts?" Turns out his bike sat in the rain on the tarmac during a layover and the box fell apart. If you're flying through some storms and not non-stop, maybe paint the box? 7) Pick a box that fits your size bike OR LARGER! You cannot put a 61cm road bike into a box that Specialized shipped a 47cm bike in!!!

[@chrisvanbuggenum871]

Ahh the good old days of GCN.

[@albertoascari2542]

Thanks for this. It's really helpful.. Mostly got the bike packed now. Older guy

[@Sutlore007]

I used to do this package with Cervelo bike's cardboard box. It is longer than the box in the video, which means I don't have to put that much effort as in the video. Just took out the handle bar and position it as in the video, took out the saddle, front wheel, wrap up the frame, put it altogether and it is done.

[@corbinwantland7669]

If you can, obtain all of the original packing material used in a new bike box sent straight from the manufacturer to your local bike shop. If your shop is friendly enough they will let you use these items if they currently have them. Typically new bikes include a few extra packing items(not shown in this video) to further help protect your bicycle. Or, you could just have them box it professionally and they usually do a pretty good job :)

[@razvanyke]

Very nice video guys, thank you !

[@joshgray9035]

I've had success with this method. A couple of tips: place a length a copper water pipe between the front forks and reinsert the skewer to prevent the forks getting squashed. And if the box has a hole on either side for carrying reinforce these with lots of tape.

[@erictofflemire8200]

Good point, but I use PVC pipe, as it has no sharp edges.

[@jfjoubertquebec]

Great video! I have been traveling with a bicycle for six years. I bring a used bicycle that I leave there and don't bring back. Saves on the hassle and someone benefits from it abroad.

[@mslf500]

I also add some polystyrene foam to the forks and rear drops outs for support and then add blocks of foam the width of the box for extra support. Good ideas here.

[@patoc2857]

Leave the back wheel on.... That is the way it comes in a bike box anyway.

[@michaelmuldoonmikesm08]

thanks guys, I just repacked mine after watching this to send it to Cape Town :)

[@crbrocket]

Might have been mentioned already but I didn't see it in the video. I'd recommend also marking the stem and seat post to know where they were originally.

[@timbridgman8236]

Great video but worth either cutting plastic tube and use the scewers or picking up front and rear fork spacers to prevent forks being squashed. When a new bike is delivered it also comes with hub end caps which are useful for no piercing the box. Remember to deflate tyres. Wrap large chairing in cardboard to help protect teeth. I also use a shoebox for pedals tools and any other items removed to reduce other baggage. Towels and clothes can also help protect frame.

[@MrRunebro]

A lot of people below are saying airlines make it mandatory to deflate tyres, and i just want to add that I flew with my bike last week in Australia, and the airline I flew on had it mandatory that regardless of the bike you ride, that you take off your handlebars, the front wheel, the front wheel was positioned near the rear wheel, and the pedals were off. So each airline has their own rules, so make sure you check what their rules are before you fly. If you're in Australia, follow what's in this video and you'll hit nearly all airlines guidelines.

[@unconventionalideas5683]

The cargo hold is not necessarily pressurized in the way the main cabin is, so it may cause burst tires if the tires are inflated. It may also be required by law in case there is an onboard cargo hold fire.

[@SaxifrageCucvara]

Great video - you make it look much easier than it is - one thing I would disagree with is keeping all parts (pedals/tools/etc) in the box - just tape them to the frame or put in another bag. I had my bike tool confiscated by over zealous security which made assembling at the other side very difficult.

[@Chazmataz0117]

Very nice and very effective

[@ukdodger]

I'd put a spare spindle or something similar in place of the wheels between the front and rear forks to stop them getting crushed. Useful vid.

[@Sansuiification]

top tip: aks your LBS for a couple of those Plastic spacers the fork and rear frame are fitted with when first delivered to the shop, then there is less chance of the handlers braking our frame or fork. ;-)

[@pedrop9788]

GCN gents, how about a video to built a box from scratch? Here is a good suggestion for you. Either you built it out of scrap boxes from the local groceries store or you get proper tick flat cardboard panels. I have not used any other method for transporting my bike in 10+ trips. Yes, I know it is a bit time consuming but it works. I would suggest to lay you frame flat on one of the panels and secure all the gear to it using electrical wire straps (certainly need to protect frame with soft cloth or padding). I always reinforce the box in these areas; forks, crank, rear-deraillouer. Then, you place that panel as a single unit with all the stuff within the box area and built the box around it. Cheers, hope you try. Pedro

[@bbengineer39]

Thank you so much 😊

[@zachwong7324]

You should reverse the stem so that it is backwards - saves space.

[@jbalatutube]

Good ideas, any videos for emtb with 3 inch tyres?

[@sax887]

excellent very good video.

[@KandiKlover]

i just got the scicon that was shown in the ad before this vid. thank you target advertising.

[@ECsponger2]

Don't forget a fork dropout spacer brace!!!

[@Patrick94GSR]

I recommend a chain with a quick link so you can remove the chain completely and carry it with the pedals and skewers.

[@sekonic1973]

I found this vid to be very useful, by the way where did you guys purchase the pipe leggings?

[@romiarkan450]

All I would do with that big bubble wrap is pop it... :D

[@cryora]

I thought of covering the box with tarp so that it also becomes weather resistant. The problem is that the tarp I just bought is flammable. Will that be allowed as checked luggage?

[@malcolmhetherington817]

Spacers for the dropouts!

[@akmalvlog6587]

I got the same box from my local specialized store and its the same and its 2019 they does not change their box as much

[@hurtadoar]

Hi! Thanks for your explanations. Do you think a X-Small Scott Speedster bike can fit, doing the same process. But instead of using a box using a cheap bag with dimensions of 70.5 x 36 x 60.5 cm?

[@danmitchell3758]

What’s it like when u re attach the berailleur. Assuming it shifted fine prior to box. Is there much tuning needed

[@koukimonzta]

why not leave the quick releases for the fork and chainstays for support?

[@dirtnastyish]

It is just blowing my mind that you took both wheels off, I will have to try that if I ever need to ship a bike again. I always leave the rear wheel on the frame and put the front one up by the handlebars.

[@mrmarcus6138]

That's a big mission he's doing taking that bike apart, you said all I have to do is take the front tire off, I think that's what I'm going to do

[@eoingray8425]

could I just wrap the frame with bubble wrap

[@MichaelAngeloSamsonPhD]

Should it be alright to put the pedals and skewers on the luggage for checkin at the airport? I hope so. That's what I'm going to do. Thanks a lot for sharing.

[@Kemo-sc7nt]

What happened

[@mbqhappy]

When re-attaching the rotor back. It seems to me that it can end up not quite at the correct angle that it was when 1st removed. How does one insure that it is re-attached correctly?

[@UmurcanEmre]

Bike is standing on chain ring in the box 🤔won't that apply axial force on bottom bracket?

[@lancelovecraft5913]

my bicycle is my only mode of transportation. I want to take it to other cities via flight but I can't get a case as i will be on my bicycle the whole time

[@moneycalling8457]

Felt bikes are excelente

[@arcoulant87]

I would have put wheel spacer between the front fork and the rear

[@SuperJacke1997]

Don't forget to deflate your tires aswell, they tend to pop during air flights due to the low pressure

[@laguintasuarez6601]

This bike was really easy to assemble kzbin.infoUgkxMesz3KOGEmwmvyKQfLfrRSUXLFzfVHZA and required very few adjustments out of the box. The wheels did not require any truing/adjustments. The frame had some small scratches, but nothing major.I did replace the seat though - the seat it came with was very uncomfortable. The tires need to be re-inflated every 4-5 days, but this appears to be quite common for the narrow 700x25 tires.Overall, in my opinion, this bike looks and rides like a much more expensive bike.

[@martinceballos9236]

Hi guys! I'm getting my first carbon bike and I need to pack it to take it home. I'm worried about having the rear triangle crushed. what's your opinion to avoid that? I was thinking on using a block of styrofoam to make the box mote resistant. ..

[@gcn]

yes, also you can put a dummy axle/old hub in place.

[@fatfruitfly5989]

Where can I get bubble wrap?

[@justinkrann7406]

my bike is only 20ibs but the allowance is 70. Is it okay I pack personal luggage in the box?

[@BEADLETHEBEAGLE]

how do you get a gcn bottle

[@ivangranados9825]

How do you call what you have used to cover the frame? cheers

[@mikeharbison8762]

Ivan Granados foam swimming noodle

[@markevasion5769]

i think you forgot to say deflate the tires - very important for non-pressurised plane holds!

[@dudeonbike800]

Nope. Atmosphere is just 14psi. Don't worry about it.

[@yoflybynight]

The entire plane is pressurized, though luggage area climate control not as dialed. If you can ship animals than bike tires no problems

[@KrisBrosnihan]

Good video. Aside from the music.

[@Gumden]

Shouldn't need to remove the back wheel.

[@Zpand3x]

I agree :) keep the rear tire on, saddle off and take the rear derailleur off the dropout like in the video. also turn the fork 180° (mabey remove front brake also)

[@cup_and_cone]

It depends on the manufacturer/box. I agree most companies use larger boxes with the rear wheel still fitted, but I still see some smaller boxes with both wheels off.

[@lesleymrick]

thechosendude he could have easily left the rear wheel and mech in place if he would have just removed the seat and post entirely. Over 90% of manufacturers send their bikes to shops 90-95% complete. Basically bars, stem, pedals, seat and seat post install. My kestrel Legend SL came with the rear wheel and mech still attached.

[@rasmusriemann6557]

those boxes are almost too large to handle

[@jamskof]

great tip about the fork and brake! thanks mate

[@LookoutLance]

I probably wouldn't do it on the gravel :)

[@thesimprebien]

whats the size of the box?

[@Catend]

what is the grey tube cushion called?

[@bihterkaytaz-eker9357]

You can find it if you search as 'pipe insulation'. I have bought recently to prepare my bike for an international flight.

[@abhinavsixfaces]

I really think you guys should address what a few people have already stated.. A plastic spacer for the fork and rear end dropouts are a must!!! Not a recommendation but a must. Especially with an aluminum frame. Please change the video...

[@markevasion5769]

how about using the hub on your rear wheel instead? oh sorry, you like exclamation marks!!!??!!!!

[@jayhenryrules]

Am I the only one who noticed that the rear derailleur cable needs a cap on the end of it? I do way too much bike maintenance...

[@omkargund677]

Size of box

[@zmertzie]

Could you use a pool noodle/foam float instead of that foam? They're thicker

[@cup_and_cone]

I used them once on a frame I sold. It worked, but the inner diameter of the pool floats is smaller than pipe insulation, so it may be harder to fit it around the tubes. I think I actually used the $1 pool floats from the Dollar Tree, which worked better than the more expensive ones, as they were a bit smaller.

[@conteudoanimal]

Free cardboard in Brasil .... 100% not possible ... here is hell place to cycling

[@Noll62]

Packing over stones seems like a bad idea to me. The wheels should be secured to the bike so they don't move around. The seat post and handlebars should be marked with tape to know where they belong when you reassemble. Use of bubble wrap is questionable. Foam seems better.

[@tcastcas1730]

Good video. Good music. BAD mixture... what are your objective(s)

[@Zer0_L1ves]

I think getting a bike box or bike bag might be a better idea... than to waste so much effort and stuff (bubble wrap, tape etc.) whenever u need to fly with ur bike....

[@gcn]

True, but a cardboard box is great if you're doing it on a budget.

[@mattd28]

+JonasVideoReview +1 on the Giant boxes they are great

[@mattbellamymate]

adamknight4862 A lot of people likely don't want to be lugging an actual bike box around with them though, and just want to unpack the bike at the airport and cycle away

[@bicycletouringvietnam-abeg4974]

Wee bit horrified. Most important - put dummy axle (spacer) in rear and front forks. Just buy a length of white plumping tube and cut to length. Needs the quick release however to do that.. Strengthens the fork and rear from potential pressure / force causing frame to break. Most important of all tips I feel (left out of video...)...??? Also...just leave rear wheel in. Doesn't need to be taken out.

[@Group51]

And this is what Eurostar wants now? Yikes.

[@winniefredbvera]

seriously.... what is with the seductive music/?? :v

[@gcordery3413]

Hope and Lust by SWW

[@austinshoupe1506]

It's dark and groovy. I dig it. Figure if it had been Meg Myers, then it's worth complaining about.

[@EmefGriffin]

Are you guys getting charged with this method? Thanx.

[@rdcanyon]

who's watching in 2018.

[@steganographer]

airlines make it compulsory to deflate tires..

[@hayes40oz]

The music on this video hahahaha I like the song but doesn't fit lol.

[@allesiofondressi2602]

Remember to deflate your bike tires too....oh, 'ang on a bit luv, do remember to redushe your tyre pressure to zed. How was that?

[@ashkanahmadi]

Good informative video thanks but PLEASE WASH/CHANGE THOSE NASTY BAR TAPES!!

[@craigc265]

all other videos say put the chain on the largest sprocket. The music has nothing to do with this and caused me to quit half way. try again lad

[@debashishkaushik6933]

that does not look good for the bike at all

[@alfredstimoli2590]

How do you think your bike got to the bike shop in the first place?

[@cataony813]

and don't forget to fly easyjet road.cc/content/news/222669-pro-cyclist-tweets-picture-bike-destroyed-baggage-handlers

[@rafaeltrujillo8210]

Me caga esa musica d fondo

[@chesepuffs1]

1st

[@BigBoy-io8kh]

So what to you do coming back? Ask for a bike box at the airport? Utter nonsense.

[@itzJuztThomas]

Big Boy Use the same box maybe?

[@mattbellamymate]

Big Boy Go to a bike shop at your destination? Utter simplicity

[@markevasion5769]

big, but not too bright

[@tvaa9758]

You are abviously not an expert in packing. Dislike!