This document describes the AirCaddy K9100 Compact (Basic AirCaddy) and the optional K8350 Aircraft Kit, providing instructions for assembling the shipping container for bicycles.

Function Description:

The AirCaddy K9100 Compact is a bicycle shipping container designed to protect a bicycle during transit. It is a corrugated box system that allows for the secure packing of a bicycle by disassembling certain components and fitting them within the box. The system aims to provide a worldwide cycling solution through creative innovations, ensuring the safe transport of bicycles. The K8350 Aircraft Kit is an optional addition that includes a metal wheel truck for easier mobility of the packed box, particularly useful for airport handling.

Important Technical Specifications:

K9100 Compact (Basic AirCaddy) Components:
- (1) B1000-00 Folded Triangular Corrugated Box: Measures 39"L x 31"W x 3"H when folded. When unfolded, its length is 39" and width is 31".
- (1) S7035-00 7MM Axle Washer
- (2) C3755-00 Large Corrugated Inserts
- (2) C3750-00 Small Corrugated Inserts
- (1) T3197-00 Metal Fork Mount
- (1) B3210-00 Metal Transit Plate (ground transit plate)
- (1) B1382-00 5MM and 6MM Allen wrench
K8350 Aircraft Kit (Optional) Components:
- (1) T3230-00 Metal Wheel Truck (replaces the metal transit plate for enhanced mobility)
- (1) B1250-00 Saddle Travel Bag
- (1) B1350-00 2 Inch Wide Tape and Dispenser
- (6) B1220-00 Flat Nylon Ties
Bicycle Dimensions for Packing:
- Maximum height from floor to top of seat tube: 30.5" (78cm)
- Maximum handlebar width: 18" (66cm)
- Maximum length of bike from fork tip to outside of the rear tire: 56" (143cm)
Warranty: AirCaddy will repair or replace any original equipment parts determined to be defective for the lifetime of the original owner. The cardboard box is designed for 4-6 trips and is not covered under warranty. A replacement shell for the K9100 is available to the original owner with proof of purchase if the outer shell wears out. The warranty applies only to the original owner and is nontransferable. AirCaddy is not responsible for failures due to improper assembly, modification, neglect, abuse, accident, or normal wear. It does not cover shipping containers used for rental or commercial use, nor the cost of repair or replacement for any bicycle or equipment other than the AirCaddy shipping container.
Patents: PATENT USA 6,039,243 & 5,520,280 & GB2345691 AND OTHER FOREIGN PATENTS PENDING.

Usage Features:

Step-1: Check for Missing Parts

Before starting, verify all components listed for the K9100 Compact and K8350 Aircraft Kit (if purchased) are present.

Step-2: Unfold the Box

Unfold the main corrugated box (B1000-00) so it resembles a butterfly from the top. Ensure the box is upside-down, with arrows and writing also upside-down.

Step-3: Continue Unfolding the Rear

Continue unfolding the rear of the box until it forms a triangle. The side facing you is the "front" of the box, and the narrow point is the "rear."

Step-4: Unfold Side Flaps

Unfold all four side flaps (top and bottom) of the box.

Step-5: Pull Front Flaps

Pull the two small front flaps from the inside of the box to the outside.

Step-6: Form the Bottom of the Box

Flip the side flaps over to begin forming the closed bottom of the box.

Step-7: Flip Front Flaps and Match Numbers

Flip the front flaps over so they rest on top of the side flap (folded in the previous step). Connect matching numbers (e.g., "1" with "1").

Step-8: Close and Tape the Bottom

Flip the last big flap over to completely close the bottom, matching number "2" with "2". Tape the free edges of the box with six or seven 8-inch strips to bridge the edges. Then, use a long, continuous strip to completely seal the edges.

Step-9: Locate Ground Transit Plate/Wheel Truck

Place the metal transit plate (B3210-00) or the optional metal wheel truck (T3230-00) at the front of the bottom of the box. Ensure the studs go through the holes into the box, connecting "3" on the plate/truck with "3" on the container.

Step-10: Flip the Box and Pull Flaps

Carefully flip the box over while holding the transit plate/wheel truck in place. The lettering and arrows should now point upright. Pull the small flaps from the inside of the box to the outside.

Step-11: Insert Large Corrugated Inserts

Fold each large corrugated insert (C3755-00) as shown in the diagrams (steps A-E). Lay an insert on a flat surface with the "A"s closest to you. Fold up the small flap at the far end (B). Crease the three folds at the near end (C) and crease them to show the two letter "A"s (D). Stand up the insert (E). Put both inserts into the shell (F). Lock the green tab of one insert into the slot of the other (G). Push the locked inserts flat against the rear of the shell to form two triangles in the corners (H). Ensure the tab of the inserts at the rear of the shell is locked.

Step-12: Prepare the Bicycle

Mark your seatpost and handlebar position for later reassembly.
Remove the front wheel and the saddle with seatpost from your bicycle.
Loosen the handlebar binder bolt just enough for handlebars to rotate in the stem.
Shift your rear derailleur to the hub's largest sprocket.
Ensure the seatpost is lightly greased.
STOP! Remove all lights and computers from the handlebar. AirCaddy is not responsible for any damage to these items.

Step-13A: Place Fork Mount (Standard Bicycles)

Place the metal fork mount (T3197-00) on a flat surface outside the box. Orient it based on your wheel size (e.g., 20"-24"-26" ATB-650C or 27"-700C). Insert the fork into the mount and tighten the wing nut clockwise. Place the bike with the attached fork mount into the box. Position the fork mount over the threaded studs protruding through the bottom of the box. Choose the pair of holes in the fork mount that allow the handlebar to be as close as possible to the front of the box without touching. Place two wing nuts over the threaded studs and tighten clockwise.

Step-13B: Place Fork Mount (Mountain Bicycles with Flat Bars - Optional)

Place the fork mount on a flat surface outside the box. Orient it based on wheel size. Insert the fork into the mount and tighten the wing nut clockwise. Use washers as needed to prevent interference. Remove the front 2 or 4 handlebar stem bolts using the provided Allen wrench (B1382-00). Rotate the stem and fork so the stem faces the back wheel. Reinstall and tighten handlebar stem bolts to the manufacturer's recommended torque settings. The front brake should face the rear wheel.

Step-13C: Place Bike with Fork Mount (Mountain Bicycles with Flat Bars - Optional)

Place the bike with the fork mount into the box. Position the fork mount over the threaded studs protruding through the bottom. Choose holes that allow the head tube to be as close as possible to the front of the box without touching. Place two wing nuts over the studs and tighten clockwise. Strap the handlebars to the sprocket side of the box at two points using flat nylon ties (B1220-00). If possible, lower the seat or place it in the plastic saddle travel bag (B1250-00) on the sprocket side. Crank arms should be perpendicular to the floor for best fit.

Step-14: Insert Small Corrugated Inserts

Fold the two small corrugated inserts (C3750-00) as shown (steps B-E). Insert them into the box toward the rear, lightly pressing against the bicycle's seat stays or chain stays. Do not let them touch the chainrings. Position the rear wheel to the right of center for derailleur protection. Always shift the rear derailleur to the largest rear sprocket for shipping.

Step-15: Pack Saddle with Seatpost

Place the saddle with seatpost into the small white draw string bag (B1250-00). Secure it to the chain side of the box with one flat nylon tie (B1220-00). Use another tie to secure the bag halfway down to prevent swinging.

Step-16: Place Front Wheel

Place the front wheel inside the box, opposite the bicycle chain. Use two flat nylon ties (B1220-00) to secure the wheel to the side of the box.

Step-17: Secure Rear Wheel

Secure the rear wheel with one flat nylon tie (B1220-00) through the horizontal rear opening. Tie a square knot.

Step-17B: Store Original Shipping Box (Optional)

Fold the original shipping box in half and store it on the sprocket side of the box, between the outer shell and the large insert. This stores the container for future use and adds extra derailleur protection.

Step-18: Close the Top of the Box

First, close the inside flap "5," then the outside flap so the "5"s match up. Next, close the flap with the aircaddy.com logo so the "6"s match up, completing the closure.

Step-19: Tape the Top of the Box

Tape the free edges of the box closed with five 8-inch strips to bridge the edges. Then, use a long, continuous strip to completely seal the edges. Print your home address and cell phone number on the label near No.6. Important: If flying commercially, do not tape the top of the box closed. Airport personnel will tape it after inspection.

Step-20: Moving the Box with Aircraft Kit (Optional)

If using the K8350 Aircraft Kit with the wheel truck, move the box by picking up the pointed end and rolling it away. Grasp the box using the lower, vertical slot. Lift the pointed end high enough to engage the wheels. Push or pull the AirCaddy for control.

Step-21: Stacking Multiple Containers

Multiple AirCaddy containers can be stacked on top of one another or nested next to each other as shown in the diagrams.

Maintenance Features:

Product Evolution: Due to constant product evolution, materials and colors are subject to change without notice.
Cardboard Box Lifespan: The cardboard box is designed for 4-6 trips and is not covered by the warranty. A replacement shell is available for purchase by the original owner if the outer shell wears out.
Support: AirCaddy provides tech support at 877-323-4083 (Mon-Sat) and a 24-hour answer machine at 708-383-5541. Email support is available at aircaddy@lickbike.com.
Assembly Responsibility: AirCaddy is not responsible for failures due to improper assembly, modification of parts or instructions, neglect, abuse, accident, and/or normal wear.
Handlebar Stem Bolts: Always tighten handlebar stem bolts to the recommended manufacturer's torque settings found in the bicycle owner's manual.
Greasing Seatpost: Ensure the seatpost is lightly greased to prevent future problems.

AirCaddy K8350 - AirCaddy K9100 Box Assembly Procedure; Steps 2-4: Unfolding and Shaping the Box; Steps 5-8: Securing the Box Bottom