Although some steps will vary depending on your bike and your choice of shipping box, here are the general steps to follow to pack a road bike in a cardboard box.
Are you ready? Let's go!
You will need Allen keys, electrical tape to mark your seat height and some packing tape for the box.
Step 1 - Remove pedals
Place the pedals horizontally parallel to the ground. Start with the pedal placed at the front. Place the #8 Allen key with the lever pointing towards the front wheel, as in the image below. (It may be a Wrench for your pedals.) Then, while pressing with one foot on the pedal, pull the lever towards you (towards the frame). You may have to pull very hard, especially if it has been a long time since the pedals were removed!
With this method, there is no need to think about left or right. We do the same thing on the other side. Place the pedal parallel to the ground at the front, place the Allen key lever forward and pull towards the frame (upwards).
Press your foot firmly on the pedal to keep the pedal in place when pulling upwards.
Once this is successful, you can breathe. The hardest part is behind you!

Step 2 - Remove the wheels
If you have quick-releases, remove them and put them in a ziploc bag.
If you have thru-axles, put the axles back in the frame and insert the small plastic pads into the disc brake. (It is VERY IMPORTANT to put these small pads in to prevent the disc brakes from closing)
Step 3 - Detach the derailleur
Before detaching the derailleur, make sure it is in its smallest position (on the lowest gear).
Using a #5 or #6 Allen key (or another, it may depend on the bike), unscrew the main screw of the derailleur to detach it from the bike. If you have electronic shifting, disconnect the Di2 cable or remove the Sram battery.
With some bike boxes, removing the derailleur hanger is not always necessary, but I highly suggest removing it! The derailleur hanger is the small metal piece attached to the frame, sometimes with two small screws. Put everything in a ziploc bag so you don't lose them.

Step 4 - Detach the Handlebar
There are a few different ways to do this. My favorite is to detach it at the head tube to keep the handlebar position intact. Remove the headset bolt, then, keeping the parts in order, remove the cap and spacers - if applicable - so you can remove the stem. Put all the spacers back in order and screw the cap back on.
If, for some reason, you prefer to remove the handlebar directly at the stem, you can use electrical tape to mark the position of the handlebar before removing it.
You want to position the handlebar against the frame to take up less space in width. Position the shifter so it does not touch the frame (use foam padding if necessary).
Step 5 - Remove the seat post
Before unscrewing the seat post, place a strip of electrical tape to mark the height. If the Shimano battery is placed in the frame, be careful when disconnecting the electrical wire. Tape it down against the frame so as not to lose it!
Step 6 - Add padding
Your bike shop should be able to provide you with padding that you can use to protect the frame. Otherwise, a few bags of clothes will do!
Step 7 - Place the bike in the box
Putting the bike in the box with two people is always easier, but if not, use a string or tape to tie everything together before sliding the bike into the box.
Step 8 - Place the wheels in the box
The way you place the wheels will vary depending on the width and length of the box, as well as how you have your handlebars positioned. You may need to make some adjustments to get everything to fit easily. You don't want to put any pressure on the cardboard walls or the frame. Everything should fit snugly, with just a little bit of play. Add protective material or a bag of clothes to keep everything in place.
If you have small plastic wheel guards, put them on to avoid puncturing the box. Alternatively, you could add a layer or two of cardboard over the area where the center of the wheel sits (tape the cardboard layer in place).
Pro Tip: Step 9 - Seal the Box and Reinforce the Handles
Once the box is taped shut, I like to add a few strips of tape around the handles to prevent tears. In the winter, or when I have a layover, I like to cover the bottom of the box (outside) with transparent packing tape to make it slide around more easily and to increase its resistance to water in case it's placed on wet ground (outside during transfers). I'll even cover up to 1-2 inches of the bottom of the box, as well as the entire length of the corners to keep my box in tip-top shape if I plan on reusing it for a few flights.
There you go, you're all set for your flight!
For more travel tips, check out the article "Traveling with Your Bike like a Pro!".
Have a good flight!
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