Technical Information

This page includes everything you need to know (and possibly some bits you never thought possible!) about our BikeBoxAlan products. From what bikes will fit – MOST! – to how to pack your bike into our boxes and more, read on for all the details that will help you along the way.

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Dimensions

Need to know the sizes and weights of your BikeBoxAlan product? Read on to find more!

Click here to view dimensions

Bike box.
Max height 92cm Min height 75cm x 113cm Long x 23cm min to 32cm Thickness. Weight 11.2 Kg.

If you are transporting your bike by Plane or courier. We always average out the dimensions, which usually results in a cheaper price. Use 80 Height x 90 Long x 30 Thickness.

Wheel Box.
74cm Height x 110cm Long x 7.5cm Thickness. Weight 5 Kg.


All Bikes Fit!

Due to its clever geometry, nearly all bikes will fit into the Bike Box Alan very comfortably.

Click here for more information

Due to its clever geometry, nearly all bikes will fit into the Bike Box Alan very comfortably with ample space for track pump, trainers, wetsuit etc, but equally important is how compact it is compared to other bike boxes. So when it comes to transporting your bike Box to and from the airport, you do not have to hire a large expensive car, and In fact you can fit 2 BikeBoxAlan boxes, 2 people and 2 medium sized soft bags into a budget priced VW Polo hatchback!

Fast to Pack. Once you have done it a few times, it should only take 10 to 15 minutes. The record is 6 minutes.

Dual purpose. Whether travelling with a road or cross country mountain bike, The Bike Box alan is the perfect companion.

Future proof. No need to worry if you should want to change your bike, there will always be a padded Velcro strap to support it.

There a couple of Exceptions. Balloon tyre bikes (Fat bikes), Touring bikes (because of the mud guards/ racks and wide tyres) Tandems (apparently it is possible to put a folding tandem in our bike box) Downhill bikes can be problematic. We recommend trying them in our box, or sending a paper template of the frame stripped to its smallest size.

Riders with 63 cm plus Bikes and 6 foot (2.85m)plus riders with Integrated seat posts. (Bikes that don’t have a removable seat pin)

Due to clever geometry the Bike Box Alan will accommodate the biggest bikes and deep dish wheels. Yet, externally the box is relatively small on the outside when compared to other bike boxes and bike bags. Meaning that up to two Bike Box Alan`s will go into a small hatch back car like the VW Polo, Fiat Punto and similar. See Pictures in “Will the BBA fit into my car” 

No matter who`s Bike Box you choose to transport the 63 cm and XL integrated seat post bikes, one has to expect an element of extra dismantling.(Bike boxes have to fall within Airlines strict dimensional criteria.)

This can result in having to remove the wheels, pedals, Handlebars, or handlebar stem, seat, or seat post, Worst case scenario Forks or chain wheels/ Cranks. Even so it shouldn’t take more than 25 minutes.

Once the bike is in the BBA you can relax in the knowledge that your pride and Joy is protected by the Unique I piece steel anti crush pole.

If you are not too mechanical you could ask your local bike shop to demonstrate the procedure. It might cost a couple of £ / $ but the experience will be well worth while.


Will my road bike fit?

All sizes of road bikes fit from 42cm to 63cm. including bikes with integrated seat posts.

Read more about road bike compatibility

All sizes of road bikes fit from 42cm to 63cm. including bikes with integrated seat posts. (Seat posts that are part of the frame with minimal adjustment up and down)

The Bike Box alan as 18 padded Velcro straps allowing bikes to be secured in 2 ways, depending on your bike size. (See the schematic drawing inside the Bike Box) The padded Velcro straps are generously sized so that any future bikes will fit into the bike box.

Riders 5 foot 10” (1.78m) or under do not have to take the seat pin/seat off.

Shimano Di2. (With seat tube battery). If you are 5foot 10” (1.78m) or less, the seat post and battery can remain connected. To remove, undo the seat pin securing bolt, IMPORTANT. Take extreme care to retain all the seat post mechanism components.

Remove the seat pin, the battery cable will be revealed, simply pull out the cable from the seat post taking care not to let the cable disappear down the seat tube, secure the cable with sticky tape to the frame.

Older versions of the Shimano Di2 may have the battery attached to the outside of the frame, frame mounted batteries can remain in place.

Deep dish wheels. Wheels up to 100 mm section can be used in the Bike Box Alan

Disc Bike Wheels/Wheel Sets. Corima, Fast Forward, Zipp 900, Zipp Super-9 and similar all fit, but the anti crush pole cannot be used.

To be 100% safe you need to transport the wheel separately in a large cardboard box or one of our wheel boxes. (See our web site)

What most people do in your circumstances is pack out with additional 25mm thick foam layer, ( like the one provided in your bike box) bearing in mind that the bike box alans wall thickness is almost double that of our rivals, so even without the anti crush pole the box does offer a reasonable amount of protection.

We do have a number of incorrectly cut intermediate bike box foams at £20 per sheet including delivery (UK mainland)

Disc brake Road bikes with through axels. This type of bike will fit into the Bike box, (see our technical page for further details)


Will my mountain bike fit?

Most Cross Country / XC bikes will fit into you BikeBoxAlan box!

Read more about mountain bike compatibility

Cross country bikes, 26”, 27.5” (650b) and 29er fit into the Bike Box Alan. Because Mountain bikes have a longer wheel base, the forks will need removing, there are only 3 allen keys to remove, this first allows the handlebar stem with the handlebars attached to be removed. The forks are then free to slide out of the frame. Care should be taken to record the position of the various spacers and lock washers that are under the handle bar stem. Once you have removed the forks the spacers should be put back onto the forks in the same order, placing the top lock down washer and bolt last, which will secure all the parts until re assembly takes place.

If you’re the type of rider who can fix things while out on the trail, packing your bike should only take you 15 minutes (now there’s a challenge for you!) Failing that consider paying your local bike shop a few £/$ to demonstrate putting the bike into your Bike Box. (See Technical section on the web site for more information).

29er Mountain Bikes

The bike box alan has one the largest internal dimensions of any lightweight Bike case. Yet it is surprisingly compact, enabling you to choose the smallest cars to transport your bike or bikes to and from the airport. (see opposite) Some brands of Bike Cases are big and cumbersome, thus preventing you from choosing the cheaper hire car, especially if you are wanting to transport 2 bike cases.

29er_large_1

All standard 26 inch, 27.5 and 29er cross country type mountain bikes fit into the bike box alan, Down hill bikes can also fit, However we the whole operation should take between 15 to 30 minutes. If you are a tall rider you should be prepared for a little more stripping down, than you would with a road bike, because Mountain bikes are generally longer than Road bikes. Small mountain bikes generally fit with the forks on. Med and large bikes will need the forks removing, (3 bolts only). if you are reasonably practical this will only take you an extra 5 minutes. In addition rear mech. seat, and pedals also have to be removed.

If you have a large full suspension bike it can be sometimes advantageous to let the air out of the rear suspension. This reduces the overall length of the bike, to facilitate loading of the bike box. re inflating the rear suspension is a simple operation. Just make sure you take a shock pump with you on your trip !

29er_large_2

26 inch wheels will fit in the wheel recess in the lid of the box providing, you deflate the tyres. If you have tubeless tyres or 27.5″or 29 inch wheels with the latex rubber in side (stans puncture prevention) we suggest you reduce the tyre pressure in the front wheel to approx. 5 to 7 ibs then install into the left hand wheel recess. The rear wheel can be placed loose in the case (see photo below)

One last tip, the rotors (steel braking disc on the wheels) are one of the most vulnerable parts of the bike ,ensure this is well protected, better still remove them from the wheel.

IF YOU ARE IN DOUBT ABOUT YOUR ABILITY TO PACK YOUR BIKE IN OUR BIKE BOX, PLEASE DONT HESITATE TO CONTACT US.

One other option is to pre arrange a visit to our workshop in Rotherham (Yorkshire) Where you can try your bike into one of our Bike boxes.

Alternatively pay your local bike shop a few pounds to demonstrate how to pack your bike into the bike box.

Or we can post you a Hire box to try (UK only) Cost £35 which includes del and collection and 1 day for you to try.

29er_2

29er Hard Tale in a Bike Box Alan

This hard tale 29er bike is for a 6 foot 3″ (1.873m) rider. The bike had a 19″(480mm) seat tube. a 24″(610mm) top tube, across the corner measurement ( from rear gear hanger to Head tube (longest part of the frame) it measures 43.5″ (1105mm)

If the geometry and size on your bike is no bigger than this one, and providing you are mechanically competent your bike should go in the Bike Box Alan. (Please see disclaimer regarding fitting a 29er in the bike box)

Guide to removal of Components

On this particular 29er bike. We removed Forks. Pedals, Seat pin ,Handle bar stem, Rear derailleur. Front tyre deflated then installed in front wheel pod, (ROTOR facing lid of box), Skewer from rear wheel used to secure front wheel, was a bit of a squeeze! to make it easier the tyre could have been removed. Rear wheel laid in box rotor facing upwards, with 10lbs of air left in.

Finally Anti crush pole, Intermediate layer of foam placed between the 2 wheels. check closure that rotors are safe. If in Doubt remove rotors.


Will my time trial bike fit?

Most Time Trial TT bikes will fit into you BikeBoxAlan box!

Read more about time trial bike compatibility

All sizes of TT bikes fit up to 63cm. including bikes with integrated seat posts. (Seat posts that are part of the frame with minimal adjustment up and down)

The majority of Aero bars can be removed by simply unscrewing the 3 Allen keys on the handlebar stem. No need to remove cables. Once removed secure in the padded velco straps provided in the bike box.

bike-thule-shipping

bikebox-bike-shipping

Some styles of aero bars may need part disassembly. A good tip is to pre mark the various settings with a white Tipex / correcting pen for accurate re assembly.

The Bike Box alan as 18 padded Velcro straps allowing bikes to be secured in 2 ways, depending on your bike size. (See the schematic drawing inside the Bike Box) The padded Velcro straps are generously sized so that any future bikes will fit into the bike box.

Riders 5 foot 10” (1.78m) or under do not have to take the seat pin/seat off.

Trek Speed Concept 9.9 and similar. This type of bike fits. We recommend either making an appointment at our works in Rotherham, UK. Or an appointment with your local bike shop to demonstrate the easiest way to dismantle and re assemble the bike

Shimano Di2. (With seat tube battery). If you are 5foot 10” (1.78m) or less, the seat post and battery can remain connected. To remove, undo the seat pin securing bolt, IMPORTANT. Take extreme care to retain all the seat post mechanism components.

Remove the seat pin, the battery cable will be revealed, simply pull out the cable from the seat post taking care not to let the cable disappear down the seat tube, secure the cable with sticky tape to the frame.

Older versions of the Shimano Di2 may have the battery attached to the outside of the frame, frame mounted batteries can remain in place.

Deep dish wheels. Wheels up to 100 mm section can be used in the Bike Box Alan

Disc Bike Wheels/Wheel Sets. Corima, Fast Forward, Zipp 900, Zipp Super-9 and similar all fit, but the anti crush pole cannot be used.

To be 100% safe you need to transport the wheel separately in a large cardboard box or one of our wheel boxes. (See our web site)

What most people do in your circumstances is pack out with additional 25mm thick foam layer, ( like the one provided in your bike box) bearing in mind that the bike box alans wall thickness is almost double that of our rivals, so even without the anti crush pole the box does offer a reasonable amount of protection.

We do have a number of incorrectly cut intermediate bike box foams at £20 per sheet including delivery (UK mainland)


Will my cyclo cross bike fit?

Most cyclo cross / CX bikes will fit into your BikeBoxAlan box!

Read more about cyclo cross bike compatibility

Cyclo cross bikes will fit into a bike box. Tyres should be deflated. 35mm tyres may have to be removed to fit into the wheel indents in the lid of the box.

Disc Brake Cyclo Cross, bikes with through axels. This type of bike will fit into the Bike box, (see our technical page for further details)

Shimano Di2. (With seat tube battery). If you are 5foot 10” (1.78m) or less, the seat post and battery can remain connected. To remove, undo the seat pin securing bolt, IMPORTANT. Take extreme care to retain all the seat post mechanism components.

Remove the seat pin,the battery cable will be revealed, simply pull out the cable from the seat post takink care not to let the cable disappear down the seat tube, secure the cable with sticky tape to the frame.

Older versions of the Shimano Di2 may have the battery attached to the outside of the frame, frame mounted batteries can remain in place.

Deep Dish Wheels. Wheels up to 100 mm section can be used in the Bike Box Alan


Will my 29er mountain bike fit?

Yes! Most 29" wheel mountain bikes WILL fit into a BikeBoxAlan box!

Read more about 29er bike compatibility

The bike box alan as one the largest internal dimensions of any lightweight Bike case. Yet it is surprisingly compact, enabling you to choose the smallest cars to transport your bike or bikes to and from the airport. (see opposite) Some brands of Bike Cases are big and cumbersome, thus preventing you from choosing the cheaper hire car, especially if you are wanting to transport 2 bike cases.

29er_large_1

All standard 26 inch, 27.5 and 29er cross country type mountain bikes fit into the bike box alan, Down hill bikes can also fit, However we the whole operation should take between 15 to 30 minutes. If you are a tall rider you should be prepared for a little more stripping down, than you would with a road bike, because Mountain bikes are generally longer than Road bikes. Small mountain bikes generally fit with the forks on. Med and large bikes will need the forks removing, (3 bolts only). if you are reasonably practical this will only take you an extra 5 minutes. In addition rear mech. seat, and pedals also have to be removed.

If you have a large full suspension bike it can be sometimes advantageous to let the air out of the rear suspension. This reduces the overall length of the bike, to facilitate loading of the bike box. re inflating the rear suspension is a simple operation. Just make sure you take a shock pump with you on your trip !

29er_large_2

26 inch wheels will fit in the wheel recess in the lid of the box providing, you deflate the tyres. If you have tubeless tyres or 27.5″or 29 inch wheels with the latex rubber in side (stans puncture prevention) we suggest you reduce the tyre pressure in the front wheel to approx. 5 to 7 ibs then install into the left hand wheel recess. The rear wheel can be placed loose in the case (see photo below)

One last tip, the rotors (steel braking disc on the wheels) are one of the most vulnerable parts of the bike ,ensure this is well protected, better still remove them from the wheel.

IF YOU ARE IN DOUBT ABOUT YOUR ABILITY TO PACK YOUR BIKE IN OUR BIKE BOX, PLEASE DONT HESITATE TO CONTACT US.

One other option is to pre arrange a visit to our workshop in Rotherham (Yorkshire) Where you can try your bike into one of our Bike boxes.

Alternatively pay your local bike shop a few pounds to demonstrate how to pack your bike into the bike box.

Or we can post you a Hire box to try (UK only) Cost £35 which includes del and collection and 1 day for you to try.

29er_2

29er Hard Tale in a Bike Box Alan

This hard tale 29er bike is for a 6 foot 3″ (1.873m) rider. The bike had a 19″(480mm) seat tube. a 24″(610mm) top tube, across the corner measurement ( from rear gear hanger to Head tube (longest part of the frame) it measures 43.5″ (1105mm)

If the geometry and size on your bike is no bigger than this one, and providing you are mechanically competent your bike should go in the Bike Box Alan. (Please see disclaimer regarding fitting a 29er in the bike box)

Guide to removal of Components

On this particular 29er bike. We removed Forks. Pedals, Seat pin ,Handle bar stem, Rear derailleur. Front tyre deflated then installed in front wheel pod, (ROTOR facing lid of box), Skewer from rear wheel used to secure front wheel, was a bit of a squeeze! to make it easier the tyre could have been removed. Rear wheel laid in box rotor facing upwards, with 10lbs of air left in.

Finally Anti crush pole, Intermediate layer of foam placed between the 2 wheels. check closure that rotors are safe. If in Doubt remove rotors.


How do my wheels fit in?

Use QR skewers off an old wheel for your front wheel. You may find a rear QR better as they are longer. If they are too long use a spacer.

Find out more about packing your wheels

Use QR skewers off an old wheel, for your front wheel. You may find a rear QR better as they are longer. If they are too long I use a spacer. a popular choice is a rear cassette extractor tool. or a pile of washers.

Depending on your wheel size and geometry the rear wheel can be left loose on top of the intermediate foam. Check for indents on the foam on closure, as this may suggest small adjustment to components to avoid them rubbing together.

All deep dish wheels fit in the BBA


Will the BikeBoxAlan box fit into my car?

YES! Due to clever geometry the BikeBoxAlan appears small when compared to bags and other bike boxes, yet will comfortably fit into most cars!

Read more information

Due to clever geometry the Bike box alan appears small, when compared to bike bags and rectangular bike boxes; Yet it can accommodate the biggest  ISP (Integrated seat post) Bikes.

As you will see from the photos transporting the bike box in your car should not present too many problems. We also have experience of putting 2 boxes, 2 cabin sized back packs, 2 average sized soft cases and 2 people in a Golf Polo (the second smallest VW):

vw-polo

Below is a 2010 BMW 3 Series with 3 doors. As you can see one box fits in comfortably with the rear seat folded:

bmw-3-series

Here is a a Mini with a BikeBoxAlan packed inside:

img_2570

And not one, but two boxes in a Jaguar XF Saloon:

img_2550


With the BikeBoxAlan box fit onto a car roof rack?

Yes! The box has a flat side so it is ideal for securing to a roof bars

Read more

The box has a flat side so it is ideal for securing to a roof bars.

  • Lay on roof bars, secure with either 6mm (1/4 inch) nylon rope or the old fashioned leather toe straps or strong plastic zip ties (cable tyres)
  • Pass through the 2 holes at the top of the box
  • Then secure at the bottom of the box by passing the rope through the caster wheel chassis.

The bike box can be secured more permanently, to be similar to a roof box, by bolting into position:

  • Lay the box on the flat side, onto the roof bars (You need the bars that go from one side of the car to the other).
  • Drill 4 equally spaced 6mm holes through the bike box to coincide with the roof bars (place a thin piece of plywood/ wood below to avoid damaging the car roof)
  • Secure with appropriately sized nuts and bolts. (The nut part should be underneath to avoid the screw protruding into the bike box)
  • Check the bolts occasionally to ensure tightness.
  • Water will be able to enter the bike box so avoid placing items in the bike box that may be damaged by water.

bicycle-travel-bike-box


Through Axels

Bikes with through axels can be loaded into a BikeBoxAlan box!

Read more!

Bikes with through axels can be loaded into the Bike Box Alan without any problems.

We recommend you use spare Traditional Quick release skewers, just the same as you would with QR regular wheels.

20mm through axels wheels will need to be fixed using a steel washer.


Will bikes with internal wiring and fixed headsets fit?

Systems vary from one bike to the next but generally the vast majority of bikes will fit

Read more!

Systems vary from one bike to the next. It’s impossible to detail the exact method to dismantle the handlebar assembly for all the bikes with internal wiring and fixed headsets.

We recommend you pre arrange a visit with your local Bike shop to demonstrate dismantling of the handlebar assembly sufficiently to allow placing your bike in the bike box, they may charge you a small some , but it’s well worth the effort.

Alternatively you can pre arrange a visit to our headquarters in Whiston Yorkshire. For a small fee, we will demonstrate the removal of the handlebar assembly.

Some of our rival bike boxes may not require the removal of the handlebars. However that style of box will not have the steel anti crush pole that you really need if you really want to protect the bike from the baggage handlers. All bikes fit in the Bike Box Alan. (See exceptions)


Disc Wheels

Will Disc Wheels fit in my BikeBoxAlan?

Read more

Will my disc wheel ( solid wheel no spokes)fit in the Bike Box Alan

To be 100% safe you need to transport the wheel separately in a large cardboard box or one of our wheel boxes. (See our web site) Having said that, our customers have never reported any problems by following the procedure below.

What most cyclist do when faced with transporting a Disc wheel (Solid back wheel without spokes) is pack out the bike box with additional packaging, such as clothing or ideally an extra layer of foam.

Bearing in mind that the bike box alans wall thickness is almost double that of our rivals, so even without the anti crush pole, the box does offer a reasonable amount of protection.

If you are having problems locating some extra foam, please email/ phone us, as we do have a number of slightly faulty intermediate bike box foams at £20 per sheet including delivery (UK mainland)


Will Disc Brake Wheels fit?

Will Disc Brake wheels fit into my BikeBoxAlan?

More information

img_2143

Disc wheel brake rotors come in many sizes. The general recommendation by Bike Box Alan and Professional riders is to remove them if they are fixed with screws. See the exception 140mm discs.

Disc Rotors are one of the most vulnerable parts on a bike, if they receive even the slightest knock whilst in transit, you risk having the most annoying scraping noise while you ride.

Removal and re fixing of the disc rotor is a relatively simple procedure, usually taking 5 minutes per wheel, you should not be concerned by any perceived danger of the re fixing of the disc, providing you fit all the screws

Procedure

The screws are star type screws not Allen keys. Initially they may be tight as some manufacturers use Lock tight adhesive, (no need to use adhesive when re fixing)

Tip. When transporting a bike with wheels removed place plastic wedge pieces or similar between the discs pad surfaces to avoid accidental closing of the gap, thus making it difficult to install your wheels later.

Using an “L “shaped Star Allen key type of tool can be difficult as you cannot get enough purchase to un tighten the star screws.  Best advice is to use a size T25 “T”shaped star tool (one with a rubber grip as per Photo below) these can be bought in expensively from Amazon. (Neilsen16 piece T handles Ball point Hex and star driver set)

img_2340

Remove the screws and the Disc rotor. Take care not to contaminate the rotor disc with oil from your bike or your skin.

Note. Most Disc rotors have direction arrows stamped into them.

Disc Rotors can be secured safely in one of the spare Velcro strap within the BIke Box Alan.

Place the Star screws back into the wheel hub for safe keeping.

Don’t forget to take all tools with you on your trip! Place them in the little bag inside the Bike box.

Alternatively make an appointment to see your local bike shop, Pay them a few pounds £/$ to demonstrate how easy it is.

To Refit, Place rotors in direction of any arrows shown. Remember the larger Disc rotor will be at the front.

Tighten screws evenly a little at a time.

Wheels with small rotor discs 140 mm diameter.

Some are fixed with star screws; some are fixed with non removable studs. These disc rotors can be safely left in place, as the bike box as a 150mm diameter recess built into the lid of the box to accommodate the disc.

img_2144


Additional Information

Facts you need to know!

Read more!
  • If your bike is damaged by the baggage handlers the maximum pay out for the total claim is £900.
  • Baggage manglers, constrained by time and a less than sympathetic appreciation of the value of your steed, receives the bikes at the top of the conveyor, he then literally ‘skims’ the bikes in their boxes or bags in what ever order they receive them.  They are then passed to a colleague up or down the baggage hold and they are then stacked 5 to 6 high.  There is no time or desire to put the stronger boxes to the bottom of the pile, so the bottom bag or box will have at least 70 to 80kg resting on it.

This is information obtained from a baggage handler and is not mere speculation.

Bike Box Alan will not collapse if several bike boxes are loaded on top. Further more, it is the only box manufacturer that dare record on film the box loaded with a £3000 Colnago carbon bike that is thrown out of a speeding car, which resulted in no damage to the bike and only superficial scratches to the box.

Bike box is designed and made in the UK by a life long traveling Ex International racing Cyclist with advanced engineering qualifications.

Bike Box Alan is the only lightweight bike box with a unique single piece of steel tube ( anti crush pole). This is positioned centrally to prevent the bike box from collapsing, even if several boxes are loaded on top, in the plane’s hold. The bike box alan is the only Bike box manufacturer that dare record on film the box being thrown out of a speeding car, with a £3000 carbon bike inside! The result being no damage to the bike and only superficial scratches to the box.

Copyrights © 2017 All Rights Reserved by BikeBoxAlan.

E&OE

bikeboxalan@gmail.com · +44 01709 365408