Traveling With A Crateworks Bike Box

Here, have a pile of weirdly specific instructional videos on how to ship an ordinary touring bike with a modified Crateworks box!

Preparing your Crateworks box to pack a bicycle into it.

Disassembling a bicycle to fit into a Crateworks box.

Packing the disassembled bike into the Crateworks box.

Getting your bike out of the Crateworks box and reassembling it.

Re-folding the Crateworks box and preparing it for shipping without the bike.

Valoria parts list

Valoria has evolved a bit since I first built her. This list is up-to-date as of January 2023.

PartCostLast Seen At
aMTBer 20T Chainring 64 BCD$‎40Amazon
Avid BB7 160mm MTB rotor disc brake #1$‎81Modern Bike
Avid BB7 160mm MTB rotor disc brake #2$‎81Modern Bike
Avid Speed Dial 7 Bicycle Brake Lever Set$‎28Modern Bike
Bacchetta 20” Carbon Johnson Fork$‎300Bacchetta
Bacchetta Compression Plug for Carbon Fork$12Bacchetta
Orbit X Crown Race 1-1/8in$7Bacchetta
Bacchetta Giro A20 frame kit, large, with Bella riser, 13” lower seat stays, 21” wide handlebar$‎800Zach Kaplan
Bacchetta Giro A20 rear wheel without tire, tube, or cassette$‎120Zach Kaplan
Bacchetta Recurve seat$‎275Zach Kaplan
Aluminum Handlebar Cup Holder$14Amazon
Busch & Müller 95cm headlight cable & 210cm taillight cable, with connectors on both ends$‎10Zach Kaplan
Busch & Müller Lumotec IQ-X Dynamo Headlight with coax connector$‎223Perennial Cycle
Busch & Müller TopLight Line Plus taillight$‎44Zach Kaplan
Busch & Müller Cycle Star Mirror 903 long curved Rod$‎37Amazon
Igaro D2 Pro R3 Dynamo USB Power Converter with coax connector$218Perennial Cycle
FSA Orbit MX 1-1/8″ headset$78Bacchetta
Jagwire Mountain Brake Inner Wire Slick Stainless, 1.5X2750mm #1$‎12Amazon
Jagwire Mountain Brake Inner Wire Slick Stainless, 1.5X2750mm #2$‎12Amazon
KMC 9-speed chain$‎65Zach Kaplan
Microshift FD-R439 Front Derailleur$‎26Modern Bike
Pinhead Bicycle Locking Skewer Set$‎43Amazon
Pitstop SS Tandem Shift Cable (3100mm) #1$‎9Amazon
Pitstop SS Tandem Shift Cable (3100mm) #2$9Amazon
Quad Lock Cycling – Handlebar/Stem Mount #1$‎30Quad Lock
Quad Lock Cycling – Handlebar/Stem Mount #2$‎30Quad Lock
Quad Lock Cycling – Handlebar/Stem Mount #3$30Quad Lock
Schwalbe Marathon Mondial Touring Bike Tire, 26 x 2.0in$‎90Schwalbe
Schwalbe Marathon Plus HS Wire Tire, 20 x 1.75in$‎50Schwalbe
Shimano Alivio FC-M4050 Crankset 170mm 40X30X22t$‎66eBay
Shimano HG400 CS-HG400-9 9 Speed Cassette, 12-36$‎41Modern Bike
Shimano PD-EH500 SPD & Flat Dual Sided Bike Pedals$‎77Amazon
SONdelux Disc hub, 32-hole$‎309Zach Kaplan
SON Junction Box with SON Hub Adapter$70Perennial Cycle
Splined to 6-bolt adaptor for SONdelux$‎25Zach Kaplan
SRAM X.7 9-Speed Rear Derailleur, Long Cage$‎59Walmart
SRAM X0 Bicycle Twist Shifter Set (9-Speed)$‎73Amazon
TerraCycle GlideFlex Stem, 1-1/8″ lower clamp, 1-1/8″ upper mast$‎135Zach Kaplan
TerraCycle Multi-Purpose Accessory Mount, 75 mm x 100 mm arms, 1-1/8″ clamps$‎38Zach Kaplan
TerraCycle Tab Mount For Euro Style Lights$‎9Zach Kaplan
TerraCycle Fastback NorBack Frame Pack$‎105TerraCycle
Tonyon four-segment anti-shear bicycle lock TY3869-20$‎30AliExpress
Topeak Road Morph G Bike Pump with Gauge$‎28Amazon
Topeak Fuel Tank with Charging Cable Hole (Large)$40Amazon
TRP Front Flat Mount Fork to Post Mount Caliper Adaptor for 160mm Rotors with two 17mm Bolts$12Modern Bike
Tubus Cargo Evo Classic Rear Bicycle Rack$‎104Amazon
Velocity Aeroheat/Dyad 20 x 1.5″ 32 Hole BMX Rim$‎73Modern Bike

Comparison of Ortlieb bags

The images here are scaled to show the relative size of the bags.

Sport-Roller Classic
25 liters
Sport-Roller Plus
25 liters
25 liters
Sport-Packer Classic
30 liters
Sport-Packer Plus
30 liters
Back-Roller Pro Classic
70 liters
Back-Roller Classic
40 liters
Back-Roller Plus
40 liters
Back-Roller City
40 liters
Bike-Packer Classic
40 liters
Bike-Packer Plus
42 liters
Back-Roller Pro Plus
70 liters

Business in Egilsstaðir

Hah, it remembered the wifi password!

Maybe I really should find some goat horns and glue them onto the helmet...

Good luck on your journey, little package!

The paperwork is out of my hands now.

So you want to stay longer in Iceland?

I get it. It’s a neat country. Also, if you get a visa extension for Iceland, you can travel all around the Schengen area with it.

It’s possible to apply for an extension without entering Iceland, by going through a consulate where you live. For example, back in my home near San Francisco, the Icelandic government has outsourced all their visa procedures to a company called VFS Global (on behalf of the Royal Norwegian Consulate General in New York.)

If you look online for “reviews” of that place, they are uniformly horrible. Calling them on the phone is a nightmare, and their website is glitchy. If you choose to deal with them you will be stepping directly into a bureaucratic swamp. That means you need to have everything perfectly prepared in advance, know their own rules better than they do, and never, ever be late for an appointment or a deadline by even a few seconds. Hooray!

I didn’t really want to put myself through that, especially knowing that the process could be derailed or delayed randomly, so I went looking for an alternate approach. I’m a US citizen, so your own needs may vary, but perhaps you’ll find this information useful.

Here is the Icelandic government’s official visa extension page, in English.

I didn’t plan to live permanently in Iceland, but I did have a job I could work remotely, so the best I could do was a “Long-term remote work” visa. That would extend my standard 90-day Schengen time, by tacking another 90 days onto the end of it.

It’s possible to travel around the rest of the Schengen area with this visa, but there’s a catch: You can only do that for a maximum of 90 days. So the idea is, the “remote work” visa gives you up to 90 additional days to stay exclusively in Iceland, during which your Schengen time isn’t depleted.

So if you want, you could spend all 180 days in Iceland, or you could spend 90 days in Iceland followed by 90 days somewhere else — France for example. But what you can’t do, is spend 89 days in Iceland followed by 91 days in France. That’s 1 day over the Schengen limit.

Since my plan was to cross Iceland by bike, which would take something like two months, getting this extension was still worthwhile for me.

Here are the conditions you need to meet:

  1. You need to be making at least $8090 a month. That’s pretty steep. It’s like 160k a year before taxes. (Official exchange rate: ) That knocks almost everyone out of the running immediately.
  2. You need to have a passport size photo (35mm x 45mm) of yourself taken and printed.
    • Thankfully there are a few conveniently located places where you can get exactly this. There’s one in Egilsstaðir, in the shopping center, next to the Arion banki. You can walk in and walk out a few hours later with three passport-worthy photos.
  3. Applications need to be printed out on physical paper. In this day and age!
  4. You need to include paper photocopies of all the pages of your passport.
  5. You need to include a document confirming that you’re able to support yourself financially during your stay in Iceland.
    • I included a printout of my recent savings statement, showing how much money I had socked away.
    • I also asked my employer to sign a letter declaring that I was employed by them and had permission to work remotely, which I printed out.
  6. You need to purchase health insurance that covers your stay.
  7. You need to pay the application fee of 12.200 ISK (about 100 bucks.) This is done by wiring money directly to the consulate via a branch of their home bank, and then including proof of that payment with the application.
    • Their home bank is called Íslandsbanki.
    • There are multiple branches in Iceland. There’s one near the East coast, in the same town as the District Commissioner of East Iceland.
    • The applicant’s name and date of birth must be included in the subject line of the wire transfer.
    • Once it’s done they will give you a receipt that you can include with your application.
  8. Applications have to be submitted at the Directorate Of Immigration, which is just outside of Reykjavík.

Since the extension can only run for 90 days post-application, you should submit your paperwork as late as possible during your stay, but not so late that the two week evaluation period causes you to overstay your current visa.

The paperwork is out of my hands now.

A word about printing:

Your best bet to get this done at a “print shop”, like this one near the capital city. Don’t rely on finding one in some small town while you’re out and about.

Your income justification letter:

Here’s a template based on the letter I used. Add your company letterhead and address around it, to make it more official.

It’s good manners to ask your employer and then provide them with a pre-made template all ready for their signature, so it’s as easy for them as possible.

September 12, 2021

Directorate of Immigration,

Dalvegur 18, Kópavogur, Iceland

Re: Remote Work No Objection Letter

Dear Sir/Madam

This letter is in reference to ———-, who has been working at ——-, in ———– since October 2nd, 2017. Currently, he receives a salary of ———- per year.

As President and CIO of ——–, I am writing this letter to confirm that ——— has permission to work remotely while traveling through Iceland this year.

——— is paid enough to qualify for the remote work visa extension, and has additional funds set aside.  Accompanying this letter you will find documents that support this.

If you need any further information, please feel free to contact me via phone or email detailed here.



President / CIO at ———-

(email address)

The results:

In my case, I submitted my paperwork on September 13th at the government office in Egilsstaðir. I got an email from exactly two weeks later on the 27th, asking me when I could come in to their office to obtain my visa.

This was a pretty decent turnaround time for a government office. Unfortunately I had already boarded the ferry boat that would take me out of Iceland, and had no way of returning to the country to appear in person at the office in Reykjavík. I replied to the email asking if there was some way to transmit the paperwork to me electronically, but they did not respond.

So, does it work? Yes, I suppose so. Didn’t do me any good, unfortunately. Without any proof that I could stay longer in the Schengen area than the usual 90 days, I just stuck to my previous plan and flew home in October.