MANTEL BIKE BOX: PACKING YOUR ROAD BIKE FOR TRANSPORT

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1 MANTEL BIKE BOX: PACKING YOUR ROAD BIKE FOR TRANSPORT

2 ROAD BIKE COMPONENTS 1 Frame: a b c d e Top tube Down tube Seat tube Chain stay Seat stay 2 Saddle 3 Seat post 4 Seat post clamp 5 Rear brake 6 Front derailleur 7 Cassette sprockets 8 Rear derailleur 9 Chain 10 Chainring 11 Crank set 12 Stem 13 Handlebars 14 Brake/shift lever 15 Grips 16 Headset 17 Front brake 18 Fork 19 Drop-out 20 Quick Release/Through Axle 21 Hub 22 Spoke 23 Rim 24 Tyre 25 Valve a c b 6 e d mantel.com mantel.com 3

3 PACKING YOUR ROAD BIKE FOR TRANSPORT 1 Mantel Bike Box and packing material This manual is a step by step guide explaining how to properly pack your road bike in the Mantel Bike Box. We ve designed the box to be used multiple times, so keep it somewhere safe together with the original packing material. In case of a return, you ll need to send the bike back in using this box. Naturally, you could also use it to keep your bike safe when going on vacation. 2 Shift the chain onto the big ring in the front, and the smallest cog in the rear. Open the quick release or through axle and remove the front wheel, followed by the rear. Tel: service.uk@mantel.com 4 mantel.com mantel.com 5

4 3 Remove the through axles or quick releases from the wheels and attach the plastic hub covers on both sides of the axle.! 6 Remove the handlebars by removing all the bolts on the faceplate of the stem. Note: hold on to the bars so they don t drop away and damage the frame! 4 Protect the shifters and brake levers with the self-adhesive bubble wrap. Fold this around the shifters and firmly press the adhesive parts together. 7 After having removed the bars, reattach the faceplate to the stem. Secure the bolts but don t overtighten them! 5 Undo the top cap and allen bolts on the sides of the stem by turning them about 2 turns. This allows you to turn the stem freely on the fork tube. 8 Undo the bolt of the seat post clamp, or open the quick release, allowing you to remove the seat post (leave the saddle attached to the post). Make sure not to get any assembly- or carbon paste on your clothes! 9 Place the cardboard plate of the Mantel Bike Box on a flat surface such as a table or workbench. Place the frame on top, with the rear derailleur over the cut-out. 6 mantel.com mantel.com 7

5 ! 10 Fold the removed part of the plate into a stack and attach the pieces to the plate using a zip tie. The crankset will now be supported by the cardboard. 13 Turn the stem in such a way that both it and the lower fork leg are flat on the plate. This way, you ll be able to properly fixate the frame later. If you re reusing the box, then there will be holes present for the cable tie. If this is the first time using the box, you ll have to make a hole yourself using a screwdriver for instance. 11 If your bike is fitted with quick releases, then place the plastic spacer in the front fork.! 14 Add protective foam to both of the fork legs. Ensure the lower fork leg can no longer come in contact with the cardboard and fixate it to the plate using a zip tie. Note: only start fixating the bike once you ve made sure it fits within the outline of the plate! 12 Is your bike fitted with through axles and disc brakes? Place the axles in the frame and fork using the cardboard tubes as spacers and protectors. Place a pad spreader between both of the calipers. 15 Secure the chain to the plate using a small piece of foam and a zip tie. 16 Wrap both the derailleur and corner of the frame with foam. Use some rubber bands to do so. 8 mantel.com mantel.com 9

6 17 The frame can now be wrapped in self-adhesive bubblewrap. Add a layer to the cardboard plate underneath the headtube, and wrap the left crank arm as well. Then fixate the right rear fork and the stem to the plate using zip ties. Secure the handlebars with two zip ties as well. 21 Let the air out of the tyres and then pack the wheels with the frame in the bike box. Place the rear wheel first, sticking the cassette through the cut-out in the plate. Ensure the cassette doesn t hit the frame! Now add the front wheel. 18 Pull the plastic bag over the handlebars and shifters. 22 Place all the separate components (such as the quick releases, etc.) in the small Mantel Box or bag, and add this to the frame and wheels. Ensure the box or bag is closed properly, or the components might roll around in the bike box, potentially damaging the bike or components in the process! 19 Finally, wrap the seat post with self-adhesive bubblewrap and the saddle using the small plastic bag. Fixate the seat post on the top right corner of the cardboard plate. 23 All done! Tape up the box properly using plenty of box tape, and attach the right shipment label for the right shipment company. Place it over the old label if this is still attached to the box.! 20 Carefully slide the frame into the box, leaving some space on the other side of the plate for the wheels. Make sure the frame doesn t come into direct contact with the cardboard anywhere! Tel: service.uk@mantel.com 10 mantel.com mantel.com 11

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