Doing things in a big way

KGS Bikes introduces the only truly safe and stable bike for ultra tall people, 6'3 to 7'6" tall. It's a Monster! Fast and beautiful with no speed wobbles, this bike is being introduced in a package with Rocket7 shoes and the Tacx Fortius VR Trainer.

Date published: Apr 6, 2007

A Clean Bike is a Happy Bike

A Clean Bike is a Happy Bike! This article goes in-depth on the way we clean bicycles.

Date published: Jul 10, 2006

How many bikes do I need?

Kevin Saunders outlines our philosophy on adapting the equipment the pros use for performance recreational cyclists.

Date published: Jun 15, 2006

Zinn/KGS Travel Bike Packing Sequence

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The Zinn/KGS Travel Bike has several advantages over other travel bikes, and packing is one distinct advantage. This packing sequence shows exactly how we make packing easy and repeatable, even if one doesn't do it often. When we deliver a travel bike, we work with you to help you learn how to disassemble, pad, pack, unpack and assemble the bike. We go through this sequence multiple times so you know what it feels like as well as what it looks like. This way, when you see the packing sequence we do on your bike your muscle memory will assist you as well as visual cues.

This packing sequence shows the bike disassembled, with the padding installed and the loose parts placed in stuff sacks. We always start with the shipping box open and the lid away from you. Notice the labels we placed for orientation of the major bike components. We will have a laminated checklist with pictures to help you with each step as well. If the checlist is followed, you should have no trouble packing or unpacking easily and consistently.

We provide a two piece security net which is a square of mesh and velcro fasteners placed on the bottom of the box, and then secured around the entire packed bike. This allows the TSA inspectors to pull the bike out of the box for inspection and to get it back in the box without damage. We also use three compression members to take the outside loads on the shipping box. The compression members are three piece units, and we place the bottom pieces in the box on top of the security net.

The first piece to go in the box after the security net is the front triangle. Note the orientation of the front fork. This will allow the rest of the triangle to fit in a way that the handlebars can fit properly later. The fork is on the right and fits in the space created by the angled wheel. Note that the KGS coupled stem is facing towards the left. This will allow the handlebars to slip in around the rear wheel and everything will fit nicely. Large bikes will still need to have the fork removed, but you will not need to worry about damaging the handlebars by removing the stem clamp repeatedly.

After the front triangle, place the rear wheel in the box, cogs down. The box is sized so you need to let all the air out of the tires in order for the wheel to fit. The tire will fit in at an angle, and will touch the bottom of the box on your left side. We put an extra layer of padding on the downtube in the area where the cogs could touch. There is a "sweet spot" where the front triangle nests easily under the wheel.

Following the rear wheel, place the stuff sacks containing the right crank arm, left pedal, skewers, chain with master link, tools, and water bottle cages in the cavity created by the rear wheel and the fork. You may have room for clothing as well. The handlebars have the cables collected in a stuff sack, and the bars are threaded into the rear wheel and around the front triangle. This is a little tricky, but is very easy if the front triangle is in the right place.  The left brake lever goes over the rim and tire, and the right brake lever goes to the outside of the tire.

While the picture shows the tops of the handlebars uncovered, they are in fact covered with padding in practice. After the bars are nested into place, the rear triangle is placed into the case. Note that the left crankarm goes up, and the rear derailleur goes down towards the left. This is why the rear wheel must angle itself into the box, so the triangle has room to be placed in the stack.

Once the rear triangle is safely placed in the case, the saddle and seatpost can be placed inside the rear triangle as shown. There is more room at this level to add clothing or shoes.

The last major component to be added is the front wheel. It will ride mostly level, but will be above the level of the lower half of the case. When adding the rest of the compression members, note that the wheel should be resting at or below the level of the compression members. This allows the members to carry the load when the case is tightly packed in the hold of an airplane, or is tossed about by baggage handlers.

The last task is to place the top of the security net on the front wheel, and tightly attach it to the lower net by use of the velcro fasteners. This will permit the components to stay together when the box is opened, and will even allow the components to be removed from the box for inspection. Please do not ignore this step! The main reason travel bikes get damaged is from improper re-packing by TSA agents. Just because the bike is out of your sight, you can still maintain a good amount of control over how they treat the bike by getting very good at using the security net.

When you have the security net in place, carefully close the lid of the case and use your fingers to ease the lid over the front wheel, which has a deflated tire. Don't forget to deflate the tires! You will not get the wheel in the box with any air in the tires.

When you arrive at your destination, the bike is removed from the case in the reverse order that it was packed. Be careful in removing the padding so you will be able to put it back on the same way next time. Each bit of padding is marked so it should be easy.

We will have a detailed article on assembling the bike, plus disassembling and padding the bike in later articles.

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Kevin Saunders

Zinn