Old 03-09-20, 02:21 PM
aka: Dr. Cannondale
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Know your bike shop, know your boxes. I pack bikes up to ship on a regular basis and always look for Trek Verve or Madone boxes. The Verves are much more common, longer than most and will put you right up against the max size for FedEx, but long enough to reverse the fork and insert the bars and levers vertically in front rather than on top. Madone/Project One boxes are clamshells with internal strapping to keep the frame steady and a separate layer for the wheels.

Worst case, get two indentical boxes for a smaller bike and cut them to make one longer or taller box, depending on your needs. These days, most shipping costs are in the dimension so the extra weight of a box you put together isn't much of a cost issue.
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