these instructions were compiled from many sources, most notably the 
  excellent info on rec.bicycles

PACKING A BIKE
==============

- call to local bike store for box
- get 2 boxes (1 cut apart for box side reinforcement liners
  (beware UPS 130" limit?)
- reinforce box handle cutouts w/tape
- get axle protector covers, fork spreaders, tube protectors from
  local bike store (are sent w/new bikes)
- buy zipties, packing tape, pipe insulation

- let some air out of tires, not all
- remove fender
- protect all tubes w/insulation, use zipties
- shift gears so deraillers close to frame
  OR remove rear derailler, ziptie to frame
- remove pedals (right is right, left is reverse)
- ziptie crank in 3/9 o'clock
- remove front wheel
- remove skewer
- tape axle protectors on to front wheel
- ziptie pump to frame

- remove computer clamp, wrap & ziptie to fork / fender mount hole
- remove handlebar
- tighten stem bolt
- ziptie handlebar to top tube: with bar-ends up, with stembolt
  underneath the down tube on crank side
- turn forks 90 deg (remove brake cable from lugs/slots to give some slack)
- loosen & turn computer pickup

- remove seat, ziptie in front of rear wheel
- fasten front wheel to frame along main triangle; put crank inbetween spokes
- all tools (ESPECIALLY ANYTHING WITH A KNIFE BLADE!) and anything sharp
  that will not pass through airport security - (note: they even took my
  pliers, so i would not be able to break into the cockpit and plier the pilot
  to death), pack in baggies, tape inside the spokes of a wheel

- slide into box
- insert sidewall liners
- pad w/foam squares or cardboard everywhere
- check that nothing rattles inside box
- insert address into box / write address inside box w/marker
- tape box

- make sure you take all tools needed to reassemble