Building the Box

The material used is 4mm corrugated plastic sheeting, just like cardboard, only made of plastic so it is stronger and waterproof.

I needed a box that was large enough to handle a size Large 29'er mountain bike. None of the existing boxes would have enabled me to leave the fork on which would have been a major pain.

The paper model used to test the folds and shape.

Different fold shapes are used for the inner and the outer boxes.

Some cuts, some folds....

Tape holds it in place until the shape is right, then bolts.

Half way there...(well, one quarter, actually)

Testing the fit...

A layer of cushion in between.

Then wheels and the lid....

Next up is the "regular shape" bike box, that this will slip into. Doing it this way means:

 - There will be a double layer of protection

 - Laying the parts in is way easier to pack that trying to slip them in through the thin top opening

 - The inner box is a shape that is hard to seal well, so the outer box will hold it together

 - The outer box is easier to seal, just a bit of tape at the top

 - Also planning to put some big bolt heads on the bottom of the outer box to add some protection and to facilitate sliding it

 - Need to figure out how to put handles onto it...

Size is 30"x60"x9"

Just realized that I am not really going to be able to test it before August unless I just ship it to CO and back...