You will need tools to disassemble and reassemble your bike - usually a set of metric allen wrenches. Potomac Pedalers does not provide these tools. If you're not mechanically inclined or you're not comfortable doing this, take your bike to a shop and have their mechanics disassemble and pack it. You should bring the required tools on your trip for reassembly, even if you don't know how to reassemble it on your own. If you're going on a guided bike tour, there will most likely be someone on the trip who can assist you with assembly. Check in advance with your tour guide.
Remove the wheels
Remove the derailleur and wrap it in bubble wrap (leave chain & cable intact)
Remove the handlebars and leave all cables attached (With an older type quill stem, it will be necessary to loosen the stem bolt and turn the bars or remove the stem from the headset. This will probably entail disattaching the front brake cable.)
Remove the pedals
Remove the seat
Lay the frame, handlebars and seat inside of the box on top of one of the foam pads
Remove the wheel skewers from the wheels and pack the wheels on top of a second foam pad with the freewheel up and the rims overlapping.
Pack your pedals and tools in a zip lock bag
You may want to add bubble wrap or other packing material around components that could rub against each other during transit - derailleur, chain, seat post, etc.
Do not lock the box because airport security may damage the bike box if they need to open it and look inside. This will render the bike box ineffectual and your bike may no longer be protected.
For more information or to reserve a bike box, contact the coordinator based in the area where you'd prefer to pick up and return the box. Karen is in MD; Adam is in Northern VA.