so i just inventoried my box stash, and basically all i have left are boxes for frames or for wheels. aside from asking the LBS for boxes, what is the minimum workable size for shipping a complete disassembled bike with forks removed? looking online for box sellers and the Boxery sells a 36x8x30 size.

My LBS always has a box, and I don't keep notes of box sizes. But 36 sounds awfully short and 30 seems an inch or two too tall. Also depends on the size of the bike.

Generally, I use something like 54x29x8, at a minimum. Leave the rear wheel on and secure the front wheel against a cushioned bike.
It works best to completely remove the stem/bar, while disengaging the cables. Makes more work for assembly, while reducing risk of scratches.
Nowadays, the larger and sturdier boxes from electric bikes work noticeably better. It adds some weight and girth, however.
You might fit a typical bike in 36x30, but it will require two boxes by packaging the wheels separately.

There is a huge jump and price once the volume goes above a certain total. Using the BIkeflights estimator I found the various limits on a traditional bike box (rear wheel on, seat, bars and front wheel removed) where shipping from Oregon to Seattle stayed under $60 rather than $160+.

54 x 8 x 30
54 x 9 x 28
56 x 9 x 28
55 x 8 x 29
52 x 9 x 30

Go over any one of those dimensions with and the price jumps $100. Of course, I ride smaller bikes so it is easier to cram my size into these boxes, but medium size bikes are fine.

As the member "Kontact" said, Bikeflights prices are jumping with around 80% more if the girth goes more than 130"
The girth is: L+2xl+2xh, example: 54+ 2x9+ 2x29=130
Another jump of the price is also at girth=105"
So, usually for a frame with fork, I must be under 105" and for a complete bike under 130".
I do not know about other companies, because I am using Bikeflights for about 6...7 years, without any problems.

Yep, that's the magic formula. I often get a box that's just a bit "too big", it's easy to cut them down to optimize the size and get under the number.

Somewhat depends on the shipping company. I think UPS and FedEx use a height, width and length total of 130 inches. Larger than that they hit you with oversize fees. I used to try to get a box from the LBS for the largest size bike I could find and under 130. I would get 2 boxes and cut the side walls off to line the inside to prevent stuff poking thru. This was back when it was cheap to ship a bike, now it's very expensive,

You can also trim it with your keyboard. If you put that the box is 8 inches wide rather than 9, no one is going to check. I did that on one box that was a hair over and it arrived without up charges. It's not like UPS staff have a lot of time to spend second guessing whether something is 8 inches or 8.5.

Bike Flights is usually UPS domestically. They are essentially making a profit by the difference between their negotiated UPS bulk discount and the retail rate. I use them because it is a much simpler process than dealing with UPS directly - and they might be a touch cheaper.

Size is important. I try to use the postal service, finding it to be the least expensive way for me to ship anywhere. To do so, the box must not exceed a certain size based on the box length (L) and girth (Hx2 + Wx2). This is how I break a bike down to fit into a box small enough for the post office to accept...

The X10 will have to fit into a box cut down to the size indicated by the black tape on the box...


Tie wrap everything together snugly. You don't want stuff rattling around or moving independently inside the box...


I crumple up newspaper and put it inside a plastic bag, then tie the top off tight. I use this method to help pad inside the box...


And these numbers indicate length of the box how size impacts shipping cost. However, once the length plus girth exceeds the postal limit, forget about it an pay a huge price for FedEx or similar shipping services...



And this is an example of how size impacts price to ship...

Could someone please advise best way to cut down boxes? I’ve searched but can’t find. Thanks

Boxcutter, straightedge, and practice.

Also, suggest that one be honest about sizing. All of the large shipping companies laser check package sizes on the big stuff to see if they can upcharge you.
My understanding is that it’s done on the line, requires no human effort, and the upcharge is done automatically.

Go to a local bike shop and get a box or two or three. Generally, they are free for the asking. Take them home and begin practice.

Disassemble the bike or remove skewers from wheels. Fit the disassembled bike frame and wheels into the original box and mark where the minimum length will be, based on the stuff in the box. Now, start to work. You want to preserve one end and one side untouched at first. I do not know how to describe this part of the process to you, hence the need for a few boxes to practice on...



You will need a tape measure, a Sharpie, or pencil or anything that marks, an Olfa Cutter, some packing tape (2 mm preferred and use lots), and something to crease with (I use the dull end of the Olfa cutter to crease the cardboard).


Solid lines are cut lines, broken lines are fold lines...







Define width once end is cut and end fold is made...



Before you fold the prepared end into the box, you need to crush the bottom of the folded end to clear the inside of the box...




It is really not all that hard to make the box fit. Just start, do one thing and then figure out what needs to be cut or folded next. Shorten the box appropriately and then decrease the height appropriately. This will be trial and error but you should figure it out before you get to box three.

Give it a shot. Get a cutter, packing tape and a few boxes and away you go.

Flat screen tv box.

Thanks so much. This is exactly what I was looking for.