Packing your bike into a hard case for the first time can feel daunting — but with the right preparation it’s straightforward, and after a couple of trips you’ll have it down to 30 minutes. Here’s a step-by-step guide to packing a BikeBoxAlan case.
What you’ll need
- Pedal spanner or 8mm Allen key (for pedal removal)
- Allen key set (4, 5 and 6mm covering most bikes)
- Bubble wrap or foam pipe lagging
- Cable ties or tape
- Track pump (useful for re-inflating at the other end)
Step 1 — Remove the pedals
Remove both pedals. The right pedal undoes anti-clockwise (normal thread). The left pedal undoes clockwise (reverse thread) — this catches a lot of people out. Use a pedal spanner for best grip.
Step 2 — Lower or remove the seatpost
Lower the seatpost as far as it will go (or remove it entirely if needed) and tighten the clamp. This gives you more space inside the box and reduces the chance of the saddle being damaged.
Step 3 — Handle the handlebars (Premium Plus only)
If you’re using the Premium Plus, you’ll need to turn or remove the handlebars. Loosen the stem bolts, turn the bars 90 degrees to sit parallel with the top tube, and re-tighten. If using the Triathlon Aero Easyfit with a TT bike, you can leave the cockpit in place — just remove the wheels and pedals.
Step 4 — Remove the front wheel
Remove the front wheel and store it in the designated slot in the box. Protect the disc or rim with bubble wrap if transporting by air.
Step 5 — Protect the rear derailleur
The rear derailleur is the most vulnerable part of your bike in transit. Wrap it in bubble wrap and secure with cable ties — or use a derailleur hanger protector if you have one.
Step 6 — Pad the frame
Wrap the frame tubes (top tube, down tube, chainstays) with foam pipe lagging or bubble wrap. Pay particular attention to any contact points with the box or wheel.
Step 7 — Deflate the tyres (for flying)
If travelling by air, let some air out of both tyres — down to around 60–70 psi. Cabin pressure changes can cause over-inflated tyres to bulge or even burst inside the box.
Step 8 — Pack and close
Place the bike in the box, arrange any kit or accessories around it (helmet, shoes and a wetsuit can usually fit alongside the bike in the Triathlon Easyfit), and close the case. Check the clasps are fully secured before labelling for transport.
On arrival
Reverse the process. Re-inflate tyres, reattach pedals (remember: left pedal is reverse thread), and do a quick once-over to check nothing has shifted in transit before heading out on the road.