Jan Heine wrote: For packing, I use foam insulation for hot water pipes. Comes in different diameters, split lengthwise, it slips onto the tubes in seconds. Not cheap - a bike's worth is about $ 5-10. If you feel the seller might have trouble packing, why not send them enough of the stuff for a bike, plus dropout spacers. That way, it'll be packed as you see fit. As Walt pointed out, you need to think about the BB shell, too. <snip>
Here's a bb protection scheme that I've used w/o getting complaints from recipients: If there is no bb assembly, I cut a length of wood (like broom handle. You don't throw these away, do you?) 1/2" shorter than the width of the box. On one end, I use a single sheet rock screw (the universal wood attachment method) through a plywood piece generally about 6"*6" (15 x 15 cm), with the attachment point offset so the bb is close to but not touching the bottom. Slip the rod through, and attache the other plate. To keep the frame from rattling from side to side, just use some twine passed around the rod and the bb shell a few times.
If the bike is being shipped with bb installed, use 1/2" plywood or two pieces of 1/4" on each side, with hole part way through big enough for the crank bolt. Use crank bolts to attach.
Not rocket science, just a little playing with the problem. Of course, the plywood pieces reinforce the cardboard at the points of contact.
harvey sachs
mcLean va