Boxing clever

[Matt2matt2002]

Test run today boxing my Raven for the flight to Marrakesh in 2 weeks.
Unfortunately the top 2 inches of the fork protrudes from the box.
Not had this problem before.
Must have used a taller box.
Size is
77 cm / 30 inches high
143 cm / 56 inches long
23 cm / 9 inches wide

I don't usually remove the forks when I pack.
Any thoughts folks?

[jags]

one box inside the other Matt.

anto.

[Matt2matt2002]

one box inside the other Matt.

anto.

Good advice. I did it in Sri Lanka for the return trip after my box had been damaged going out. Thanks for jogging the grey matter.
I think this will be the solution.
Matt

[mickeg]

If you do pull the fork off, assuming you bring a phone or tablet or camera, it might come in handly later to have a photo of all the parts of your headset in the correct order.  Or the exploded diagram.

My Nomad, I put all the headset parts in the correct order and correct orientation on my fork after I remove it from the frame.  Use something (in the photo used a rubber band) to keep everything from falling off the fork while in transit.

[John Saxby]

Matt,

On my last trip Down Unda, I started with a fat-bike box, which was 10" wide and 32" high.  (I had to cut that down so that it was 38" long, so that it fitted within the 80" total linear dimensions allowed on my flight.) 

If you can get a 32" high box, that might save you the hassle of removing and then refitting the forks.

If not, then George's suggestion makes very good sense.  The exploded diagram of the FSA headset is valuable -- when reassembling my forks, the lower bearing cage went walkabout across the garage floor, and I wondered, "Which way up did it go?"  Corollary 93B of Murphy's Law dictated that the 50% chance worked against me, and it took a bit of fiddling and close reading of the FSA diagram to get it right.

Good luck in any case.  Look forward to your tales of Morocco.

Safe journey/safari njema (as they say in East Africa),

John

[Matt2matt2002]

Thanks folks.
Problem solved, I think.
I returned to the lbs with the intension of bringing home a second box to fit over the top of the first box.
A bike sandwich kinda thing.
However inside one of the boxes was a second smaller one the right size to ' cap ' the protruding fork top tube.
I will cut this smaller box down slightly and am pretty sure it will do the job.

I am away for a week so will do the final pack on July 28th.
Stand by for perfect pictures of completed task.
Or plenty of panicking requests for further advice.

Thanks again for all advice/ opinions.

[mickeg]

I assume you have the little plastic piece that goes on the bottom of the fork so that the fork dropouts don't puncture the bottom of the box and make a mess of things.  If not, go back to the bike shop and ask for one.  They usually are packed that way on a new bike.

[Matt2matt2002]

Thanks Mick. Yes. I've acquired 4 over the years. And since the weigh next to nothing, I usually take a spare in the box.
I also found some stoppers for the seat post. And probably one for the fork head.
Thanks for the heads up though.
At my age I never mind being reminded or given tips.
Always something to learn. And at 64 3/4 always something to forget.

[mickeg]

... And at 64 3/4 always something to forget.

Sounds like you are about 1/4 year ahead of me.