I've been able to ship 63cm bikes through USPS in compliance with the 108 inch size limit, but it takes two boxes; one for the wheels and one for the frame. And you have to scrupulously minimize the size of the box around the frame to meet the size limit. I had to repack a frame once when I didn't notice the box I scavenged from the bike shop was 8 inches wide instead of 7 inches. The two extra inches (girth measures top and bottom width) put me at 109 inches, and the clerk at the desk had no sense of humor.
Of course you have to remove the wheels, pedals, seat post, handlebars, and drive side crank (or at least the chainrings, which is probably too much work) to get a 63cm frame to fit. The seat cluster is then the tallest point on the frame. You may or may not be able to leave a seat post in there for protection. On one extremely long frame I had to cut another inch off the height of the box to meet the 108 inch limit. A smaller frame is obviously easier. With the fork spun 180 degrees, the length of the box is about 40 inches, which gives you 27 inches for height, assuming a 7 inch wide box. 40 + (2 x 27) + (2 x 7) = 108. Amazing on my frames how often the height is exactly 27 inches.
It is possible to leave the handlebars on if you unwrap one top section to enable you to slide the bars towards the back of the bike after twisting them 90 degrees to the right or left. I usually just unhook the brake cables, pull the whole handlebar assembly and ship with the wheels. You may also have to pull the front brake and spin the fork 180 degrees to shorten the frame a few more inches.
Two boxes through USPS has always been cheaper than one big UPS or Fed Ex box, but I don't know about Australia and USPS Global Express rates. As always, stuff that box full of non crushable packing material to prevent the mail gorillas from mangling the bike. I usually put removed items in with the wheels box to avoid having loose items roaming around with the frame, scratching the paint.
Tom Adams, Shrewsbury NJ
>From: DTSHIFTER@aol.com
>To: lynnmiller@optusnet.com.au, classicrendezvous@bikelist.org
>Subject: Re: [CR]Shipping a bike.
>Date: Thu, 30 Oct 2003 06:59:48 EST
>
>
>In a message dated 10/30/03 2:24:50 AM, lynnmiller@optusnet.com.au writes:
>
><< Could anyone here tell me the least expensive way to get a bike from the
>US to Australia? I have been quoted some very hideous prices. I am sure among
>the collectors here, there is plenty of bike shipping experience. >>
>
>Morning Lynn,
>
>The least expensive shipping is usually with the US Postal Service, however,
>they limit the size of a package shipped to Austrialia via airmail parcel or
>economy (surface) to a maximum of length + girth = 79". If you go with USPS
>Global Express, the size gets increased to 108" which is barely enough to fit a
>complete bicycle (with creative packing) as long as it's not a very large
>frame. Global Express should be much less than either UPS or FedEx however.
>
>UPS and FedEx are very expensive (I know) and I have been told by a few folks
>that Airborne Express is much less than UPS & FedEx, but I have no direct
>experience with that carrier.
>
>Best,
>
>Chuck Brooks
>Malta, NY
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