How to Pack a Bike for Shipping or Air Travel in a Cardboard Box

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If you’re getting ready to move your bicycle through the mail or via air travel, you may be wondering how exactly you’re supposed to get it packed in a cardboard box. After all, bikes are uniquely shaped and often bulky in size, and standard shipping boxes aren’t often designed to accommodate those rare attributes. But with a little guidance and the right supplies, packing a bike in a cardboard box is not only possible, but it’s easier than you might think. Whether you’re boxing up your bicycle for shipping, a long trip, or some other reason, here’s is how to pack a bike in a cardboard box.

1. Find the Right Bike Shipping Box

Don’t let the name fool you. The U-Haul Flat Panel TV Kit is perfect for boxing all kinds of uniquely shaped items, including bicycles. The kit is designed for packing flat screen TVs up to 70”, so it’s more than capable of accommodating a standard adult bicycle that has been prepped for shipping. The included two boxes telescope to fit a variety of sizes. If you don’t have a designated bike box or bag on hand, consider a Flat Panel TV Kit as a safe and economical alternative.

Order a TV Box

2. Gather Packing Supplies

Be sure you have the right packing supplies on hand. Not only will these items protect your bicycle from scratches and scuffs, but they also make packing a bit easier. U-Haul carries a variety of versatile packing supplies that can be used to protect all kinds of items, including your beloved bicycle.

Recommended Bike Packing Supplies:

Packing a Bike

3. Disassemble the Bike

To fit your bicycle in the Flat Panel TV Kit (or a similarly shaped box), you first need to do a “30 percent tear down.” If you’ve ever bought a bicycle that came in a box, then this might look familiar – it’s how many manufacturers ship bicycles to retailers or straight to customers.

Parts that need removing:

  • The seat and seat post
  • The pedals from the crank
  • The handlebars from the stem
  • The front wheel

4. Wrap the Bike in Bubble Cushion

Protect the frame by wrapping it in Enviro-Bubble, starting with the top, bottom, and seat tube. Secure the Enviro-Bubble with Mover’s Wrap instead of tape so no sticky residue is left behind on the frame. Attach the handlebar to the front fork and top tube using Mover’s Wrap. Be sure all exposed sections of the frame are wrapped in cushion, including the drop out, stem, seat post, and pedals. In general, using more cushion is better, so wrap the bike until you feel it’s well protected.

5. Sandwich the Front Wheel

Sandwich the front wheel between the two Small Moving Boxes. Be sure the boxes are flattened, like how they come brand new after you buy them at a U-Haul center or similar retailer. Use Mover’s Wrap to sandwich the wheel between the two boxes and keep everything together. Mover’s Wrap only sticks to itself, so you don’t need to worry about using tape yet. H2: 6. Place the Bike in the Box Place the bike frame inside the inner TV box. Then place the pedals, seat, and front wheel to the side of the frame inside the box. Don't worry if the frame or wheel are slightly exposed at the opening, especially if you have a larger frame. The kit’s telescoping feature is designed to pack items this way. Finally, slide the outer box over the inner box to effectively ‘close’ the kit.

7. Tape the Box

Use shipping/strapping tape to secure the boxes. First, place several strips perpendicular to the box opening to keep the two boxes from telescoping, then tape the box seam to keep it secure. Use as much tape as you feel comfortable to ensure it’s safe in transit.

That’s it! It’s that simple to pack your bicycle like a pro and get it ready for transit. If you’re ready to box up your bike and start adventuring, get your bike shipping box and packing supplies today!

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