Flying with bike (in a bike box)

[Binky]

Wasn't sure which forum to post this so I'll try here.
I'm a regular visitor to Mallorca for holidays and cycling and so far I've always hired a bike there and in Menorca.
However, I just found local to me a bike box for sale so I went for it so next trip (probably in a week or so) I'll be taking my own bike.

Any specific dos and don't or general tips please share. I did a trial run this afternoon of packing bike in box and after a bit of faffing it seems all good. It's a Bonza hard shell case so protection will be fine I think. Plenty of padding etc.

 

[ianrauk]

Just make sure your tyres are deflated.
Also make sure you weigh the box and bike. Its very easy to go above the permitted weight.

 

[HLaB]

My main tip, you are already sorted for is to get a hard box. My other tip is too practice putting the bike in the box and reassembling it. The last time I flew with a box, I had to deflate the tyres to get them to fit. There was a slight sealant leak but the main anxiety was whether or not they'd re-seat. The two tiny Stans race sealant bottles and the CO2 cannister done their job though. I maybe should have carried an extra couple of cannisters though 🙃

 

[Binky]

My main tip, you are already sorted for is to get a hard box. My other tip is too practice putting the bike in the box and reassembling it. The last time I flew with a box, I had to deflate the tyres to get them to fit. There was a slight sealant leak but the main anxiety was whether or not they'd re-seat. The two tiny Stans race sealant bottles and the CO2 cannister done their job though. I maybe should have carried an extra couple of cannisters though 🙃

I don't use tubeless so no issue with sealant, I'm old school inner tubes. I found during trial run I had to remove handle bars, pedals, saddle and wheels so it's a bit of a faff.
I think deflating tyres is required anyway whether tubeless or not. As for weight, bike, box, track pump and shoes/helmet came in under 25kg so I'll stuff in whatever else I can under 32kg which I believe is usual airline limitation. I've got Di2 so any issue with battery? I REALLY don't want to have to remove as that's a no-go as it's a Canyon bike and farcical situation of battery is in downtube and to access you have to remove cranks and bottom bracket!(yes really).

 

[Dogtrousers]

I don't use tubeless so no issue with sealant, I'm old school inner tubes. I found during trial run I had to remove handle bars, pedals, saddle and wheels so it's a bit of a faff.
I think deflating tyres is required anyway whether tubeless or not. As for weight, bike, box, track pump and shoes/helmet came in under 25kg so I'll stuff in whatever else I can under 32kg which I believe is usual airline limitation. I've got Di2 so any issue with battery? I REALLY don't want to have to remove as that's a no-go as it's a Canyon bike and farcical situation of battery is in downtube and to access you have to remove cranks and bottom bracket!(yes really).

This is a thing that crops up on here from time to time (along with flying and CO2 cylinders and letting the tyres down) I'm not sure whether we got to any definitive answer. See, for example this recent thread: https://www.cyclechat.net/threads/jet2-di2.302880/

See also this: https://bettershifting.com/5-things-to-think-of-when-flying-with-your-di2-bike/

 

[Pblakeney]

came in under 25kg so I'll stuff in whatever else I can under 32kg which I believe is usual airline limitation.

I'd check that before you pack. In my experience it has varied between 23kgs and 30 kgs.
Some airports are lax but some are looking for the fee. Usually on the return. I always seek confirmation of size and weight acceptance and this has saved me additional fees twice.

 

[Binky]

This is a thing that crops up on here from time to time (along with flying and CO2 cylinders and letting the tyres down) I'm not sure whether we got to any definitive answer. See, for example this recent thread: https://www.cyclechat.net/threads/jet2-di2.302880/

See also this: https://bettershifting.com/5-things-to-think-of-when-flying-with-your-di2-bike/

Ha! Interestingly I'd posted on the first thread in the link, I'd forgotten about that. Removing Di2 battery not an option so I'll just keep quiet and cross my fingers.

 

[Animo]

I have a Bonza too. It has served me well over multiple trips per annum over the last few years.

I once collected it and found that most of the clips had popped open so now I use a few thin zip ties through the little holes. I carry a few extra in my hand luggage in case they want to open it at the airport and I need to put more on.

I deflate tyres and take a mini pump rather than CO2. It's all pretty stupid but airport staff aren't always the most reasonable. Once witnessed an entire group of cyclists having to open their bike boxes at an airport and hand over the cartridges.

I take the chain off with reusable quick link. Saves it flapping around in the box and making a mess. I also take the rear mech off the hanger, bubble wrap it and tape to the frame. Probably overkill but my bike is a big size and only just fits in the box.

Roll of masking tape is good to tape things on/down. Padded envelopes for tools, pedals, chain etc and then tuck them behind the foam.

You'll find over time you work out a method which suits you and your bike. Always best to sort it a few days before you travel rather than the night before!

 

[HLaB]

I don't use tubeless so no issue with sealant, I'm old school inner tubes. I found during trial run I had to remove handle bars, pedals, saddle and wheels so it's a bit of a faff.
I think deflating tyres is required anyway whether tubeless or not. As for weight, bike, box, track pump and shoes/helmet came in under 25kg so I'll stuff in whatever else I can under 32kg which I believe is usual airline limitation. I've got Di2 so any issue with battery? I REALLY don't want to have to remove as that's a no-go as it's a Canyon bike and farcical situation of battery is in downtube and to access you have to remove cranks and bottom bracket!(yes really).

The airlines tell you to deflate the tyres but you don't really have to unless you're planning on going into outerspace, its similar to carrying co2 😉

 

[Cathryn]

Having done it twice in August (there and back), my best tips are:
* get there in PLENTY of time. Bike boxes are unwieldy and it takes time to move around the airport.
* check in as early as possible and get a friendly person (rather than machine) to help. It's never straight-forward.

 

[classic33]

Take a roll of tape with you, in case you're required to open it for inspection.

With regards the zip ties, get some in other than black or clear. You'd not believe how easy the locks open. With the zip ties and locks you're making anyone who might be interested in looking, look elsewhere.

 

[Binky]

I have a Bonza too. It has served me well over multiple trips per annum over the last few years.

I once collected it and found that most of the clips had popped open so now I use a few thin zip ties through the little holes. I carry a few extra in my hand luggage in case they want to open it at the airport and I need to put more on.

I deflate tyres and take a mini pump rather than CO2. It's all pretty stupid but airport staff aren't always the most reasonable. Once witnessed an entire group of cyclists having to open their bike boxes at an airport and hand over the cartridges.

I take the chain off with reusable quick link. Saves it flapping around in the box and making a mess. I also take the rear mech off the hanger, bubble wrap it and tape to the frame. Probably overkill but my bike is a big size and only just fits in the box.

Roll of masking tape is good to tape things on/down. Padded envelopes for tools, pedals, chain etc and then tuck them behind the foam.

You'll find over time you work out a method which suits you and your bike. Always best to sort it a few days before you travel rather than the night before!

Regarding the Bonza box, the guy I bought it from said was only suitable for rim brake bikes(which I have) due to method of fastening wheels using quick release but I don't see why not suitable for bikes with through axle such as discs. Is your bike rim brakes? Just thinking if I get a disc bike in future.

 

[Debade]

For piece of mind, you might want to include one of the air tag suitcase trackers.

 

[Animo]

Regarding the Bonza box, the guy I bought it from said was only suitable for rim brake bikes(which I have) due to method of fastening wheels using quick release but I don't see why not suitable for bikes with through axle such as discs. Is your bike rim brakes? Just thinking if I get a disc bike in future.

I used it with a disc brake bike last time out. Used a bit of cardboard in each wheel axle hole to adapt them so the skewers fit snugly.

 

[wakemalcolm]

Cabin pressure is the equivalent of 5-8000 feet, so unless you'd deflate your tyres for going up the Stelvio or the Tourmalet (I'd take a few psi off myself) then don't bother.
Of course, if challenged by ground staff, lie till your pants are ablaze rather than try to explain any laws of physics.