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Airline Bike Travel

For once, people with small road bikes (compact frame, 650c wheels) have an advantage over the taller folk. It's possible to take your bike as checked baggage on flights without incurring bike charges, even with the newer airline baggage rule, e.g. 2005 onwards.

If you use a bike box, bike handling surcharges vary according to airline. But it's typically $50-$90 each way. Plus they make you sign a waiver stating that they're not responsible for damage.

I used to use a slightly oversized hardshell case originally designed for a folding bike (perhaps the Dahon Montague). The case easily outweighed my bike, but it provided excellent protection.

With minimal disassembly, e.g. wheels, handlebars, fork and seatpost, my smaller road bike including the wheels fit comfortably inside the hardshell. The case measured 32" x 26" x 12.5". Total linear dimensions of 70.5", which is over the 62" limit set by the airlines. However, before the increased scrutiny that checked baggage received after 9/11, I was usually allowed to check that in as one of my two pieces of checked baggage without any oversize charges. Over a number of years, I took my bike all over the country, to Europe and to Asia, and only got charged once. After 9/11, it was simply not possible and I had to come up with another method.

According to the rules, you are allowed two checked bags each of which must not exceed total linear dimensions (W+L+H) of 62ins (157cm). The maximum weight of each bag must not exceed 50lbs (23kg). Older rules used to state 70lbs. Nowadays, for bags between 50lbs to 70lbs most airlines will add a surcharge. For lightweight racing bikes weighing a total of 15-16lbs (7kg), the weight limit is not a factor even with additional clothing, shoes, tools and helmet.

In my case, I have a custom Litespeed Ghisallo that uses 650c wheels. The wheels weigh a negligible 5lbs or so in total and can simply be placed in a regular suitcase, as shown below on the left.

The suitcase measures 30" x 22" x 10" (62 linear inches) and is a standard size. The wheels simply fit diagonally as shown. For size comparisons, I have placed that suitcase adjacent to the oversized hardshell case I mentioned earlier, as shown above on the right.

The rest of the bike disassembled as shown below fits in the 33" wheeled duffel bag shown below. This is my 2nd piece of checked luggage. At 33" x 14" x 14", it also satisfies the airline baggage restrictions.

[If you can send the wheels on ahead, or have a set of wheels you can borrow, you can get away with only the wheeled duffel bag to hold all your stuff, which is collapsible and makes travelling pretty convenient.]

Assembly and disassembly can be easily accomplished in a leisurely 20 minutes. Only tools required are:

  1. Two allen keys: 5mm and a 4mm (for the Ritchey stem bolts).
  2. Pedal wrench.
  3. Crank remover and a crank bolt socket tool.
Note the rear derailleur is removed and placed in the rear triangle. All other components can be placed in ziploc bags next to the frame. I use clothing in clear bags to cushion the frame from damage.

So far, I've used this system for about 3 years without damage.

Sandiway Fong
2006


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