I thought I would write a really helpful post (with pictures) about how to pack your bike, since I think its one of the most daunting thing about competing overseas. However even though I have now done it countless times, I still got it a it wrong while preparing for this post, so I might keep it as my own reference too!!
Step 1
Take off all the accouterments you have attached to your bike and give it a good clean, chain included.
*This is the part I always forget!!*
Take of the pedals at this stage. Yes you can do it later, but it is LOADS easier to do it now, especially if they have been over tightened or you have really been generating some big wattage!
Step 3
Turn the bike up-side down, this makes the next bits much easier.
Step 4
Take the wheels off and deflate the tyres. My bike box came with some wheel bags, however they were just thin flimsy canvas, so I lined them with some bubble wrap.
Step 5
Some bike boxes come with a spacer to keep the chain taught and out of the way. I lost mine so I have improvised with some nylon ties.
Step 6
lay the bike in the box. you can now take the seat post and handlebars off without the frame getting damaged on the floor, and the chain getting grease on carpets and any soft furnishings.
Depending on you box and bike depends on what part of the handlebars you need to remove, a bit of jiggery-pokery and you will work out what fits best.
Step 7
Most boxes come with straps, so strap your bike in nice and securely. Mine also came with these foam spacers. I like to wrap one around the seat post, so that if it comes loose and rattles around the box it limits the damage to the other bits in there. The other one I put around the top tube, simply because it fits nicely there.
Step 8
Fill you box with other bits and bobs. How much you can et in will depend on the combined bike and box weight. This is where there is a false economy with cheap boxes, as they are generally heavier, and if you don't have a feather-light bike, you might find only bike and box are under the weight prescribed by the airline. Usually 23kg is allowed, but obviously you need to check with your airline.
Step 9
Make sure nothing is handing out, or going to get trapped in the hinge. I nearly severed a gear cable as I was trying to squeeze the box shut, and didn't realise it was trapped in the hinge!
Bike Box by B&W http://bike-cases.co.uk/product-bike-box.php#sthash.TNPPAxvu.oVhBT7e0.dpbs
