This looks like the final packing configuration less the chain and RD removal. Hopefully, I can get a few more miles in on it before packing for the trip. I just wanted to get this sorted early in case I ran into issues.

As for t he front brake disk there is plenty of room between the disk and the frame. The closest spacing is to the water bottle and it will shift if necessary. I will still use a well secured disk protector on both sides of the front hub.

With the front wheel tied to the crank, fork, and stem it is not going anywhere and makes a convenient handle for putting the bike into the box. The only remaining issue is that the shift levers are closer to the box wall than I would like. I think that I'll wrap some cardboard around the bar ends to add some space. I will also add some "bike box" white foam to various bits to prevent rubbing in transit. This stuff seems to work as well as pipe insulation but is less bulky to carry with you.