How to pack a Bike Box Alan Premium

The Bike Box Alan Premium is the gold standard bike box and has been since launch. It is only now, with the development of integrated stems that require a box where the handlebar stays in place, that its supremacy is challenged. While the newer triathlon Aero EasyFit and the recently launched Road EasyFit allow for lazy packing (wheels off, pedals off and you are done) these are more expensive and far less common than the premium.

There are also a couple of other advantages to using a premium –

·      It is a smaller box overall so easier to get in and out of cars & taxis

·      The smaller footprint has no edges or corners to get caught on luggage belts

·      If with a group, it is easier to lay the premiums flat or place on a roof rack.

·      Smaller means tougher – check this video of one being thrown off a viaduct.

·      It is cheaper to rent a premium over an Easyfit

You do need to have a little technical know-how to pack a premium but it is really easy once you have done it a few times.

Packing Bike Box Alan Premium

So here is a step by step how to pack a bike box alan Premium.

·       Open the bike box with the wheel compartment as a lid

·       Use the gear levers to put the chain on the smallest ring at the back and largest at the front. This makes it easier to remove the rear wheel.

·       Turn your bike over so it rests on saddle/handlebars.

·       Reduce air in tires to about 30%

·       Remove front wheel and secure in front wheel recess in lid of bike box (for disc brakes try disc out) using the shorter quick release skewer to secure through the lid.

·       Remove rear wheel from frame and secure in rear wheel recess, using the longer skewer, with gear cassette next to the lid. For disc brakes, if you find your rear disc rubs against the tyre of the front wheel you may need to adjust. You can also lay the rear wheel on the foam as you close – it doesn’t necessarily need to be attached to the lid.  The aim is to get both wheels to fit comfortably together so try different ways to find what works for your wheel & tyre combination.

·       Make sure the spokes are not in the way of the anti-crush pole recess (turn wheels to leave a gap where it will go)

·       Once wheels are removed, change gear down to move the derailleur to the middle.  

·       Remove the pedals (facing forwards right hand pedal has right hand thread, left hand pedal has left hand thread)

·       Place the frame into the box, as per instructions (look at sticker top left of wheel recess) depending on size, typically drive train down.

·       Remove handlebars by loosening (not removing) the nuts at the headset.

·       Take the handlebars off and twist to lay where they fit which might be over top tube, between top tube and downtube or nearer the forks. They will 'find' a spot that works subject to the play in your cables.

·       Use velcro straps to secure into box.

·       Mark / measure your seat post height, then remove or lower into the frame if you can. Its a good tip to note your measurements and maybe take a small tape measure to remove guesswork. You'll also feel very pro rebuilding.

·       Fasten the velcro straps around the frame and check for any movement

·       Use any spare velcros to strap in the pedals, saddle/seat post and pump/ tools etc.

·       Place any tools, ideally wrapped in bubble wrap or bagged, under the bottom layer of foam at the bottom.

·       Put any other soft kit in bags and place in / around bike

·       Replace the anti-crush pole and place the intermediate foam layer over the bike

·       Close the lid carefully, with one hand guide the anti crush pole into position, do not force anything.

Disc wheels in Bike Box Alan premium

Couple of Tips:

·       There are more velcros in the box than you will likely use. It caters for multiple ways of packing - you haven't missed something.

·       Use Zip ties just before you hand the bike box over for extra security - but make sure you have a way of cutting them off at the other end.

·       You can put tools in a freezer bag inside your waterbottle or wrap them in bubble wrap and put them under the foam at the bottom.

·       I don't recommend packing all your gear in with your bike - use your hand luggage allowance. You don't want to make the box overweight and get charged.

·       Only put your shoes in the box on the way back, that way, if the box goes missing or is delayed (doesn't happen often but...) you have them and could still rent a bike. 

·       Use additional bubble wrap / pipe lagging for additional protection if there are any areas close to rubbing or near the box sides.

·       For wider tyres (700x30 / 700x32) you may need to deflate to around 30%, fit one in the cavity and lay the other on top of the foam.

·       For tubeless, take a small pack of sealant in case of any leakage so you can top up, if you have a good seal you won't need it.

·       Put a luggage label on your bike frame just in case

·       Add a removable sticker on the box with your contact details.

·       If you have one, add an Airtag in.

·       Tie a bandanna or similar to the box to aid identification - you don't want someone else collecting your bike.

To rebuild:

·       Undo velcro straps, loosely re fit handlebar stem & saddle while in box, lift out and place frame upside down, re-fit pedals then the wheels. Turn over and centre front wheel then tighten stem and stem cap bolts, inflate tyres, adjust saddle.

·       Double check everything

·       Quick test ride and then check once again that everything is tight

Model - Premium

Max Dimensions Height 95cm x 117cm Long x 32cm Thickness. 

Weight 11.2 Kg (without bike)