The best bike packing in the worldWe use a stiff, expensive custom cardboard box. It costs $30.
We use foam blocks that cost about $5 each to pad the bike in various spots. Some of these are custom cut for us, some we cut up ourselves. Some slip over tubes, some are hot-glued to the sides of the box.
Then we use other foam for special padding purposes, to keep fenders or other parts from rubbing on themselves or something else.
Robert developed the method, then taught it to Mark, who taught it to Eric, who taught Emil who you see in the video. Later on, Will learned it and taught it to Steve.
It takes him about two hours for a normal bike.