MANTEL BIKE BOX: PACKING YOUR ROAD BIKE FOR TRANSPORT

1 Frame: Top tube Down tube Seat tube Chain stay Seat stay

2 Saddle3 Seat post4 Seat post clamp5 Rear brake6 Front derailleur

7 Cassette sprockets8 Rear derailleur9 Chain10 Chainring11 Crank set

ROAD BIKE COMPONENTS

abcde

1 1213

15

14

16

17

18

19

20

21

22

23

24

25

5

2

6

3

7

8

4

9

10

11

a

cb

d

e

17 Front brake18 Fork19 Drop-out20 Quick Release/Through Axle21 Hub

12 Stem13 Handlebars14 Brake/shift lever15 Grips16 Headset

22 Spoke23 Rim24 Tyre25 Valve

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PACKING YOUR ROAD BIKE FOR TRANSPORT

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.

1

Mantel Bike Box and packing material

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: 020 3695 9922Email: service.uk@mantel.com

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3

Remove the through axles or quick releases from the wheels and attach the plastic hub covers on both sides of the axle.

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.

7

After having removed the bars, reattach the faceplate to the stem. Secure the bolts but don’t overtighten them!

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.

6

Remove the handlebars by removing all the bolts on the faceplate of the stem.

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.

!Note: hold on to the bars so they don’t drop away and damage the frame!

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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.

11

If your bike is fitted with quick releases, then place the plastic spacer in the front fork.

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.

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.

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.

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.

!

!

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.

Note: only start fixating the bike once you’ve made sure it fits within the outline of the plate!

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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: 020 3695 9922

Email: service.uk@mantel.com

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