Packing Guides

Pack/unpack time: 20 min/25 min

Buxum Bike Box - Fly Your Bike by Airplane - Strong Secure Storage for Cycling Events and Travel

1 Prepare bike:

a. Engage top gear
b. Remove bottle cages
c. Undo cable connectors – normally two for gears and one for rear brake
d. Remove pedals
e. Remove saddle/seat-post assembly – protect assembly by placing it in draw-string bag (sold separately to box)
f. Remove crankset
g. Remove front brake caliper from fork – protect caliper by placing it in draw-string bag (sold separately to box) *Note: often not required for bikes with long cable run
h. Remove handlebar/stem assembly (Note: for most bikes, removing handlebars only will suffice)
i. Remove wheels and deflate tyres
j. Remove wheel skewers
k. Disconnect two S&S Couplers
l. Attach protection sleeves (sold separately to box) – these are marked according to corresponding tube/component – be careful to tie chain to RH chainstay
2 Load front half of frame to box base with fork blades pointing up – note position of frame relative to box latches
3 Load rear wheel to box (on top of front half of frame) with block facing down – end of axle should contact centre of floor of box – block should be to left of downtube. Ensure block is not in contact with downtube. *Note: This step requires locating wheel over Anti-Crush Bars such that spokes do not rub Anti-Crush Bars – differing spoke patterns normally means a degree of trial and error here – we suggest you make a note/mark of the optimal position.
4 Load rear half of frame to box (on top of rear wheel) with derailleurs facing down – note position of frame relative to box latches. Manoeuvre rear half of frame to the position where it lies lower-most in the box.
5 Load handlebar assembly to box – this requires threading it between rear wheel spokes above frame top and head-tubes. Manoeuvre and re-position to achieve the lowest possible location in the box base.
6 Tuck bagged front brake caliper in a convenient space
7 Load saddle/seat-post assembly to convenient space in box such that it doesn’t protude able highest point of rear half of frame (inside rear triangle, between seat stays normally works best).
8 Insert Anti-Crush bars and attach to velcro ring on base base of box. A far as possible, try to position the two Anti-Crush bars opposite each other (i.e. spaced 180 degrees) on Velcro ring.
9 Pack loose items such as cranks, pedals, skewers and bottle cages in protective bags (sold separately to box)
10 Load front wheel to inside of box lid – this is held lightly in place by rim on lower edge of lid
11 Load any other items (e.g. shoes, pump, tools, spare tyres) to spare space in box.
12 Carefully partially lower lid – check to ensure that Anti-Crush Bars enter the box lid without touching spoke of front wheel. If they do then open lid, rotate a couple of degrees and repeat until lid closes cleanly.
13 Check that edges of box base and box lid are positively engaged on all four sides.
14 Engage and two latches by turning handle through 90 degrees.
15 If required, lock case by threading the TSA-approved cable locks through latch handle and cable guide.
16 You’re all done – safe travels!
17 To unpack, the reverse of these instructions applies.

You’re all done – safe travels!

Pack/unpack time: 10 min/10 min

Buxum Bike Box Easy to Pack - Fly Your Bike by Airplane - Strong Secure Storage for Cycling Events and Travel

1 Prepare bike: Engage top gear. Remove pedals. Remove saddle/seat-post assembly. Remove wheels and deflate tyres. Remove wheel skewers.
2 Prepare box: Open box, remove Anti-Crush Bar and wheel bags. Slide the Rear Axle Mount to forward-most position.
3 Place saddle/seat-post assembly under webbing in base of box – saddle towards front of box.
4 Position the cranks horizontally with right-hand crank forward.
5 Load frameset to box:

(a) Front: Locate front fork dropouts to Front Dropout Mount, adjust and tighten QR skewer (as with a bike, quick release may need adjustment to accommodate lawyer tabs).
(b) Rear: Manoeuvre rear end of bike such chain locates in groove Rear Dropout Mount. Slide Rear Axle Mount backwards to engage with rear dropouts. Tighten quick release as you would on the bike.
6 Remove handlebar from stem by removing end cap on stem (for quill stems and integrated handlebars, remove whole bar/stem assembly from fork).
7 Rotate handlebar through approximately 90° and lower into box adjacent to right hand side of front fork and headtube. Consider additional protection (e.g. pipe lagging) to brake levers.
8 Place wheels in wheel bags. Place pedals and skewers in pockets inside wheel bags (there are two pockets in each bag).
9 Load wheel bags to box, one each side on frame – on right side. Front wheel goes on left hand side at rear of box. Rear wheel goes on right hand side at front of box (with cassette facing outwards). The slots in the wheel bags must be positioned horizontally and adjacent to one another in centre of box.
10 Insert Anti-Crush Bar through slots in wheel bag and locate ends in one of three locations in Anti-Crush Retainer (note that you should use same location point on left and right side).
11 Load any other items (e.g. helmet, shoes, track pump) to spare space in box (these should be housed in suitably protective bags to prevent damage during transit).
12 Manoeuvre box lid over box base, taking care to ensure lid is correctly oriented by aligning two red washers on front end panels. Take care to ensure that lid clears handlebar/stem assembly. Check that upper and lower edges are positively engaged on all four sides of box.
13 Engage and tighten four latches by turning handle through 90 degrees.
14 If required, lock case by threading the two (one on each side) TSA-approved cable locks through latch handle and cable guide.
15 To unpack, the reverse of these instructions applies.

You’re all done – safe travels!

Pack/unpack time: 5 min/5 min

Buxum Bike Box Ventoux - Minimal Disassembly. Big Strong Secure Storage Box. Fly Your Bicycle.

1 Prepare bike: Engage top gear. Remove wheels and deflate tyres. Remove seat post.
2 Prepare box: Open box, remove Anti-Crush Bar and wheel bags. Slide Rear Axle Mount to forward-most point on carrier.
3 Place saddle/seat-post under webbing in base of box.
4 Load frame to box. Cranks horizontal, right-hand crank forward.
5 With rear chainstays resting on Rear Axle Mount, insert front dropouts in Front Axle Mount and tighten quick release as you would on the bike (as with a bike, quick release may need adjustment to accommodate lawyer tabs). Note: there will be some movement in the Front-Axle Mount – this is accommodate a range of head-tube angles and fork rakes.
6 Manoeuvre rear end of bike such chain is over Rear Axle Mount. Slide Rear Axle Mount backwards to engage with rear dropouts. Tighten quick release as you would on the bike.
7 Place wheels in wheel bags. Load wheelbags to box, one each side on frame – on right side (looking from rear of box) located forward and on left side located rearward. The slots in the wheelbags should be oriented horizontally and adjacent as shown in photo.
8 Insert Anti-Crush Bar through slots in wheel bag and locate ends in one of three locations in Anti-Crush Retainer (note that you should use same location point on left and right side).
9 Load any other items (e.g. helmet, shoes, track pump) to spare space in box (these should be housed in suitably protective bags to prevent damage during transit).
10 Manoeuvre box lid over box base, taking care to ensure lid is correctly oriented by aligning two red rivets on front edges. Check that upper and lower edges are positively engaged on all four sides of box.
11 Engage and tighten four latches by turning handle through 90 degrees.
12 If required, lock case by threading the two (one on each side) TSA-approved cable locks through latch handle and cable guide.

You’re all done – safe travels!