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. Remove cassette and freewheel assembly Pack end caps, cassette and freewheel and skewers in small parts bag. Deflate tires, drain out sealant. Wipe out excess sealant. Set wheels aside.

Step 3: Disconnect cables:

 Disconnect three quick couplers. Disconnect front brake at caliper. Also remove computer sensor from fork leg.

Step 4: Remove rear derailleur. Remove chain. Put chain & master links in its own bag.

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.

If the cassette is still attached, try to find something to "armor" around cassette so it doesn't dig into the down tube. Then install a sheet of packing bubbles on top of the wheel.

Step 11: Insert handlebars.

Set shifter levels straight back. Insert bars under everything that's already in the box, 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: Install parts bags and filler material.

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