Here at Ruckus Composites, we receive and ship frames every day. For most people though, it’s a rare experience, and the best way to package your frame for shipment is not always obvious. We’ve seen all sorts of things used as shipping material, from your usual packing peanuts or bubble wrap, the contents of a recycling bin, to throw pillows, or even absolutely nothing.
First things first: the box.
You don’t need a full-sized bike box to ship a frame. However, you can usually get a frame-only box at your local bike shop. If they don’t have a frame-specific box, try a BMX-sized bike box. Barring that, cut down a full sized bike box. 8 x 30 x 36 should fit anything but the largest seatmast-bearing frames. Remember not to cut down too small: you want to have room around the contact points of the bare frame.
This brings us to the next consideration. The places on your frame most likely to get dinged or damaged in shipping are the four main box contact areas.
These are the dropouts, the ends of the headtube, the bottom of the bottom bracket, and the seatpost clamp. However you pack up the frame, these four areas should receive special attention. While at your favorite bike shop ask them for a rear dropout spacer.
This plastic piece comes with new bikes and fits into the rear dropout to add stiffness to the rear triangle and resistance to crushing in the event the box comes under a side load or is stacked sideways. You can also use an unlaced hub, a piece of 10 mm threaded rod with appropriate hardware, or even rolled and taped corrugated cardboard cut to length and zip-tied into place.
Now, to wrap up your frame. The absolute easiest effective way to wrap your frame is to get a large bubble bag, like a moving company might package a mirror or painting in, and put the entire frame inside.
Tape it up with masking tape and you’re done. Alternatively, rolled bubble wrap can accomplish about the same thing, and others have good luck with pipe insulation. Always use masking tape or low-tack painters’ tape so that if you do have to apply tape to the frame itself, the danger of tape pulling off clearcoat and graphics (it happens!) is minimized.
Once you have your frame wrapped up with the four contact areas padded and a dropout spacer installed, it’s time to stick it in the box. But wait! Don’t just drop it in and let it rattle around. Get a roll of stiff paper (or a stack of newspaper if that’s easier) and start crumpling.
Pack paper under and around your frame to immobilize it inside the box. Once everything is nice and cozy, tape up your box with your favorite packing tape and take it to your favorite shipper.
Address it to:
Ruckus Composites
REP#[your repair number]
3380 SE 20th ave
Portland, OR 97207
Once that’s done, give us a call or email us your tracking number and we’ll keep an eye out for your frame. Once we receive your frame we’ll inspect it for any damages and send a follow-up confirmation email.