When you pick up your new bike from a local bike shop all ready to go there was a whole process that happened before it was ready to roll. This had to happen before you could get a fit, or even put your cheeks on the saddle. This process is called building a bicycle.

Building a bicycle frame up is much different than building it out of the box. My next bike review I hope to be building up a bike from scratch and will outline over the course of a dozen or so posts the basics of building from scratch. This post isn’t about that, instead it is explaining to you what a mechanic goes through when your bike comes “out of the box.”

What does out of the box mean? It means that 60-95% of the bike is assembled when it is pulled from a long, tall and narrow box. The box normally has multiple languages giving warnings about proper assembly. Many companies don’t allow a consumer to build their bicycle themselves. Instead a mechanic at a dealership has to be the on to do the initial build and has to get to you ready to ride. Once it arrives to you fully built what you do with it is your choice.

Depending on what level bike and what company it is coming from there are different stages a bike can come out of the box. It can have everything on but front wheel, seat post/saddle, pedals and handlebar. It might need its hydraulic brakes bled or fork and shock installed.

The Trek Fuel EX that I picked up last week was about 89% built. The seat post/saddle, handlebars, front wheel, front caliper, front brake cable, and pedals were not installed. I wish the front rotor hadn’t been installed at the factory as it ended up somewhat bent.

The very first thing I do when I pull the bike out of the box is grease the seat tube. I then install the seat post which normally has the saddle already mounted on. This allows me to clamp the bike in a work stand. Next I cut off th 15 zip ties that are holding the front wheel and handle bars to the frame. Around the frame is tons of packaging. I pull off Styrofoam, bubble rap and cardboard to finally get to the bike.

Now this “out of the box” bike is ready to be fine tuned.

This post is part of my on going build up and review of the ‘08 Trek Fuel EX 5.5. Check it out.