At each end of the box I add additional layers of carboard for protection. Pay particular attention to the front cutaway. If this box is dropped on its end the headtube will take most of the impact force. If its dropped on the lower corner there's a void which takes up the force. If the fork was turned forwards it would take the force on the impact regardless of how the box was dropped.






Seapost is zip tied to the seat tube:


Box is reinforced where the front axle will rest:


Seat and pedal go in smaller box. smaller box is dropped into big box:



Seat tube is reinforced with a cut off seatpost. I wrapped 4 layers of cardboard aruond the exposed post and zip tied it inot place. This is the first time i used this method. Usualy I pad it with 2 layers of pipe insulation and4-6 layers of cardboard.