This ones heading to China....

I tapped the loose headset parts together then tapped it directly to the top tube. There's open air in that area of the box so its no big deal for it to be out in the open like that.

The fork legs are on each side of the seattube. I used an old axle and quick release in the rear dropouts. The seatpost is taped to the seat stays.

At the end of the box by the dropouts I inserted a bunch of cardboard. There's something like 6 layers at that end!!! The headtube actually rests on the bottom of the box. I have it wrapped in 2 layers of pipe insulation with 2 layers of cardborad tucked in front of and underneath it. Adding in the box thats 4 layers of cardboard.

Before anyone asks its a 1986 Schwinn Peloton built with Colombus SL/P tubing. Shipping was $95 plus $10 for my time and materials.

I sent a Merlin to Australia somewhat like that, cut the box down and put PVC pipe crossmembers at each corner and through the BB. Then I ordered all the parts the Aussies can't get over there, had them shipped to me, and used them to fill the gaps. $323 and was there in four days. The "group" of buyers split the shipping up amongst themselves. I think there were about 40 different items plus the frame, most of it eBay and WhyMor items.

Only thing I would add Jim is some more cardboard that is the same width of the box above the frame to help with box rigidity. I just received a frame with a damaged top tube that was packed like yours. If the box had been a little stronger from a crush to the corner I am sure it would not have been damaged.

Here's another one I did. If I had to do this one over again I would have used a 7" wide box but both local stores nearest to me were out of boxes.. All of the parts are taped or zip tied to te frame in areas that in a void.

not too shabby.

miamijim, I've used your "guide" here for all the bikes I've shipped, two personal and six or seven facilitations. In each case the bike arrived in 100% perfect condition.

The real key here is the pipe foam. One the frame is covered it becomes the solid attachment point for everything else that's loose. It's an inexpensive, safe, and easy way to get a bike form A to B in perfect condition. Lift fork through the box notwithstanding

I kind of doubt it it was but please tell me it wasn't a 60cm frame.

Nope. If I remember correctly it was a 56 or 58.

Nice. I take the same precautions. Even when shipping just a couple states away.

Looks great, whoever gets that mixte is going to be very happy.

I hope so, anyway.

I think he'll like it.....

I'm sure he will...it's her who counts though!

I wish the shop that packed my new acquisition had seen this...

I have packed up hundreds of frame sets and bicycles, sending them as far away as Australia. And I do not go to near the lengths some of you do. And, I have had two bikes damaged, both the result of crushed boxes that few protective wraps could have withstood.

I must finish up the article on how to ship bikes frame etc. But for now, a quick tip - Poor Person's Bubble Wrap...

Take a plastic grocery bag. Fill it 1/2 to 2/3 full with crushed newspaper. Then tie the top together tight, trapping air inside the bag.

Now give the bag a bit of a squeeze. Do not try to pop the darn thing. Just squeeze it. And watch the crushed paper draw air back into the bag as the paper expands. This stuff is great packing material for bikes and frame sets.

And I invented it!!!

^ that sucks but at least it didn't hit the decal, and there are lots of shades of red nail polish to choose from

The actual mummification in pipe foam takes only 20-30 minutes. Disassembly another 20-30. Planning positions in the box strapping big components to the frame another 20-30. Final pack, cut down box if required, box loose components, seal etc. another 20-30. So, I guess I spend 90-120 minutes or so packing a bike. I don't consider it "lengths"...I consider it a wise investment in time to protect someone's purchase as well as possible. Especially when facilitating the buyer deserves that.

You're not kidding brother! I was kinda paranoid about this bike, though. I don't even want to think about how many hours this took me...I'll do it again, however, for anyone wishing to safely ship from the NJ area. For a scant $500 packing fee.

For patina, I would agree, or just touch it up with a protective clear coat. This, on the other hand, just makes me livid.

I'm trying to secure the funds to pay a professional to fix this.

Now that's how I'd like to see a bike I paid for arrive! Jim's packing is right on the money, too...how I like to do it, the wooden crating is a bit over-the-top, but if you have the scrap wood handy, it can't hurt to over-build. God knows, the shippers will always discover new ways to defeat even the best packing job given enough chances. I like seeing the old inner tubes (and other trashed parts) recycled for packing and bracing purposes.

geez... that's some crazy packing. even foaming up all the tubes is a little over kill in my book. those bikes are packaged much better than any manufacturer would ship a new frame. basically they are just shrink wrapped but in a custom sized box. i think construction of the box to fit precisely, and reinforced around the corners is the most important thing. when i ship frames, i just foam up the head tube, put something rigid between the dropouts,, maybe pad the BB area and seat tube area, throw the fork into a couple of usps boxes, throw some plastic wrapping around the frame and add lots of filler paper. never had any issues, shipping as far away as sweden and new zealand. i always figure if a package is destined to be damaged, most likely it will be so severe that no amount of padding will help. then you are just out of luck and take your lumps. but bravo to those who are really going that extra mile... err 10 miles with packing.

I tend to agree with you that a major catastrophe is not preventable with any measure of packing diligence. However, my wood frame could potentially prevent crushing that a cardboard box couldn't. Also, I was shipping a vintage frame that is not replaceable. And unlike the manufacturer of high end modern frames, I was not in a position to absorb the cost of damaged merchandise.

I'm going to start experimenting with empty trash bags and expanding foam.