Wednesday, January 4, 2017

Packing My Bike with S&S Couplers in the Travel Case

Greetings Esteemed Reader! I'm not writing this for you. I'm writing this for me. But maybe it can help you to. So without further ado...

Step 1: Remove accessories and pedal.

Including handlebar bag, seat bag, computer, lights, etc. Pack these in zip lock or other bags and set aside.

Step 2: Remove wheels.

Remove hub end caps with leatherman if applicable. Pack skewers in small parts bag. Deflate tires, set-aside.

Step 3: Remove 1 front and 1 rear brake each, which are attached to the cable.

 Also remove computer sensor from fork leg.

Step 4: Remove rear derailleur. Disconnect front derailleur cable.


Step 5: Remove stem 


Disconnect both from bars and steer tube. Pack stem in bubble wrap, fit bottle cages around it. Put small hardware in zip lock bag.

Step 6: Remove seatpost & saddle. 

Put seat clamp in small parts bag. put foam sleeve around seatpost.

Step 7: Disconnect front and rear triangle.


Step 8: Wrap all tubes in foam.


Step 9: Reconnect front triangle and fork, place in bottom of case.


Photos doesn't show these parts wrapped cause I figured out later I should wrap them before packing them. Duh.

Step 10: put rear wheel in the case, cassette side down.


Try to find something to "armor" around cassette so it doesn't dig into the down tube.

Step 11: Install handlebars.

...with one drop in the back right corner, outside of the wheel, and the other drop threaded through the spokes in the wheel.

Step 12: Install the rear triangle 


...with the drive side down and the bottom bracket in the back left hand corner

Step 13: Install the support pillars.

This means sliding the pillars under everything you just packed in and through the spokes in the wheel wherever they will fit.

Step 14: Stuff filler material in there.

Stuff more durable fabric materials such as frame bags, seat bags, jeans, booties, gloves, etc in nooks and crannies to help stabilize and cushion everything.

Step 15: Install the front wheel.

Put it in the bubble wrap bag, try to line up the previous holes in the bag with the pillars.

Step 16: Finish!

Put the caps on the pillars, zip it up, and crank down on the straps!

Notes:


  • buy cable de-couplers for front der
  • remove rear der. to protect hanger and derailleur, rather than disconnecting the cable
  • Label the foam tubes as to what frame part they go on, maybe tape them on
  • pack box at least 24hours before departure
  • write a nice note to the TSA asking them to be careful re-packing when they inspect your bike bag
  • remove axle end caps on hub, if applicable.
    • if traveling a lot in the future, consider building wheels with removable end caps, and on which the freewheel/cassette can be removed by hand as this save a lot on the overall width of the packed bike

And here is all the special stuff you should pack:


Group
Qty
Item
Notes
On Bike
1
Lock

On Bike
1
tail light

On Bike
1
headlight

On Bike
1
handlebar bag add a wrap for tools if they are going in here to prevent rattling & damage 
On Bike
1
saddlebag or frame bag… for tools, etc.
On Bike
2
bottle cages

On Bike
1
Schrader Valve Core Adaptor

On Bike
2
mudguards

On Bike Tools
1
hand pump

On Bike Tools
1
spare tube

On Bike Tools
1
multitool, with chain tool

On Bike Tools
0
Co2 cartridge not allowed on airlines!
On Bike Tools
1
Co2 head

On Bike Tools
1
S&S Wrench

On Bike Tools
4
chain links

On Bike Tools
2
master links/pins

On Bike Tools
1
patch kit

On Bike Tools
2
tire levers

Shipping
3
bracing pillars

Shipping
1
bike case

Shipping
3
bubble wrap bags/sheets for wheels or between wheels/frame
Shipping
-
foam tubes for wrapping around frame tubes
Shipping
4
zip lock bags to pack smaller parts
Spare Parts
2
Skewers spare
Spare Parts
1
1 1/8” headset cap

Spare Parts
4
replacement spokes

Spare Parts
2
shifter cables

Spare Parts
1
brake cable

Spare Parts
1
valve core

Tool Kit, Off Bike
1
bottle chain lube

Tool Kit, Off Bike
1
hypercracker

Tool Kit, Off Bike
1
Spoke wrench

Tool Kit, Off Bike
1
Spoke holder

Tool Kit, Off Bike
3
Spare sealant bottles

Tool Kit, Off Bike
12
Towels

Tool Kit, Off Bike
8
Nitrile gloves

Tool Kit, Off Bike
1
fiber spoke

Tool Kit, Off Bike
1
pedal wrench whatever works for the pedals you brought!
Tool Kit, Off Bike
1
5mm allen wrench

Tool Kit, Off Bike
1
4mm allen wrench

Tool Kit, Off Bike
3
small cable ties

Tool Kit, Off Bike
3
large cable ties

Tool Kit, Off Bike
1
permanent marker

Tool Kit, Off Bike
1
USB charger cable for lights

Tool Kit, Off Bike
1
cable snip

Tool Kit, Off Bike
1
air guage

Tool Kit, Off Bike
3
hose clamps

Tool Kit, Off Bike
1
small container of grease



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