I'm on pins and needles awaiting my latest bicycle to arrive to Georgia from California, should be here Friday. The bike shop who I've dealt with before felt it best not to dismantle the front end, ( wires, conduits, fore-brake, etc.). It was packed in an oversized heavy duty electric bicycle box 77" x 37" X10" at weighed in at 74 lbs. I couldn't get Bike Flights to accept a box that large, when I called the Bike Flights customer service line the rep told me to shave a few inches off the height from 37 to 35" and width to 9" when I returned to the online box dimension page and adjusted the box down it allowed the bike to proceed.
I asked the rep if I could do as he suggested, his reply was I'm not telling you to do that but.... he also stated not to worry FedEx would not measure the box. It's currently in Oklahoma in transit and has made it through a few facilities so far.
I'll keep you posted on it's condition when it gets to me this week.
Mike