Managed to pack my bike on my own—wahoo! Can’t wait to unpack this in Cairo and find out whether I did well enough to keep things safe, or screwed up big time. Fingers crossed for now!
Step 1: Take off the front wheel
Step 2: Remove the pedals
Step 3: Remove the seat post
Step 4: Fasten the seat post screw (so it doesn't get lost)
Step 5: Remove the handlebar
Step 6: Screw the handlebar bolt back on (so it doesn't get lost)
Step 7: Protect the frames
Step 8: Stabilize the fork
Step 9: Make sure the chain is on the smallest crank
Step 10: Fasten the handlebar, i.e. tie it firmly to the frame
Step 11: Remove the bottle cages (should have done that upfront)
Step 12: Secure the pedal crank by tying it to the frame
Step 13: Protect the rear derailleur
Step 14: Remove the quick release skewer from the front wheel
Step 15: Cover the wheel hubs
Step 16: Cover and protect any other sensitive parts
Step 17: Build the cardboard box and/or secure the bottom with tape
Step 18: Carefully lower the bike into the box
Step 19: Add the front wheel and any spare non-folding tires
Step 20: Reinforce the box near the wheel hubs with additional cardboard to prevent breakage
Step 21: Securely package all loose parts—pedals, front wheel skewer, bottle cages, etc.
Step 22: Add seat post, box with loose parts, bike packs etc.; paper and foam for protection
Step 23: Close the box, and use lots of tape to reinforce corners and hand holds
Step 24: Tape name, contact and flight details on both sides of the box
Step 25: Arrange special airport transport (as the box may not fit into a normal car)
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