Trick for cutting down a shipping box

[Steve in SLO]

For those of us who ship bikes, linear weight charges are the norm, so it behooves us to cut down boxes to the minimum safe size to save $$ on shipping. I recently figured out a pretty cool trick for when I needed a box which was shorter in length that I had on hand.
Cut the box off to the Required length
Trim off about 1/2 inch height of the side walls of the shorter portion ( so the top flaps can lay flat) and and insert into the main box.
Take an awl, Phillips screwdriver or similar and poke through the box from the side. I use four sets of holes which are 2-3 inches apart.
Starting on the inside take a large zip tie and pass it through the holes and pull it tight, thereby binding the two pieces of the box together.
Finish with some tape to keep from snagging the free end of the box
Pack it up!

This technique is a lot more secure than trying to do it all with tape, as the box end tends to telescope, thereby loosening up the box.

[Spinner]

Nice work. Thanks for sharing.

[bironi]

Nice solution.
Thanks!
Byron

[Pegoready]

Nice Trick!

Smaller box= safer and cheaper so this is always worth the effort.

I have a carton stapler specifically for this purpose but they're kind of big and expensive. This is a better trick for occasional need.

[WNC rider]

When I cut/trim boxes down like that, I glue the cut-off/"insert" part to the main box. I feel like this also helps add strength/rigidity to the overall box.
On the "insert": glue on the bottom, glue on the sides, then tape the open "ends" of the main box together to compress everything and keeping the sides of the insert pressing against the main box.
I also glue any closure flaps together when doing final sealing of the box (along with using packing tape). I prefer Elmer's Glue All.

Haven't had a trimmed down box come apart yet, but I've had quite a few "complaints" from people who have had a difficult time opening packages I've shipped them with glued flaps/closures.

[cmbicycles]

I did that a few times when I was buying and selling more. Then I bought one of these carton staplers, used, on ebay and it was well worth the $ IMO. No tape necessary for anything, and I've gone several years on a half box of staples so far.H-1024_3.jpg

[dave thompson]

I use a hot glue gun for fastening cardboard-to-cardboard, stiffeners and reinforcements.

[blak_byke]

As a person unloading a few frames...I thank you!!

My previous method was cut, fold and massive amounts of heavy duty packing tape. It wasn't pretty, but it sure was water resistant. This is way more elegant.

[charliedid]

clap clap clap

[NHAero]

Clever - thanks for sharing that!

[nelsoc]

Putting this into practice this week. Many Thanks.

[batman1425]

I do a similar trick but have never used the zip ties, thanks for that!

Another good idea - take some strips of cardboard and fold into a triangular prism as long as the width of the box or a tiny bit longer. Tape in place and you have some super strong anti crush braces.

I pop a few of these in after the bike or wheels are packed and they not only keep the contents from sliding around too much but are remarkably strong if you pay attention to which axis of the cardboard you are using.

[timto]

Love it thanks for sharing

[Spaghetti Legs]

Nice technique. I’ll shorten boxes but they always look like they just arrived from a 3rd world country via tramp steamer before they even leave my house. I’ll try that out next time.

Extra tip for infrequent or novice shippers - if shipping just frame and fork, remove the fork and secure to the down tube to shorten up the box even more.

[Steve in SLO]

Originally Posted by Spaghetti Legs

Extra tip for infrequent or novice shippers - if shipping just frame and fork, remove the fork and secure to the down tube to shorten up the box even more.

I do something like this on most of my frame/forks. Does allow several inches less box.