How to box a bicycle for airline travel
- Get a box
- Remove pedals
- Remove seat post
- Detach rear derailleur (shift to smallest cassette ring & largest chainring, pad and tape to frame, leave cables attached)
- Partially deflate tires
- Remove front wheel (it’s a good idea to put an old axle with quick release or plastic packaging plug for the front fork, and then pad it well)
- Turn handlebars sideways or detach altogether & secure to frame with zip ties
- Drop bike in box, place front tire next to fork
- Add foam padding and/or packing material (foam noodles, bubble wrap, electrical tape) – ask the bike shop if they have any extra from new bikes they have been recently assembled
- Zip tie wheel to fork/frame (if you can keep fork from resting on the floor of the box it offers extra protection
- Pack any additional tools, lubes/grease, gear in panniers or stuff sacks, secure to frame. If this bike box is the only bag you will check, make sure that any items prohibited in your carry-on baggage are also here (liquids, stoves, multi-tools, pocket knives, etc…)
- Don’t take over handle slots box; you don’t want anyone dropping the box.
The best case scenario is that TSA can lift your full bike/gear conglomerate as a unit straight up and out of the box without anything falling off. Assume that handling may cause a hole or two in the box, so make sure there are no small or medium sized loose parts floating around the box. Always carry-on your helmet.
For the return leg (if applicable), save the box, packing materials and extra zip ties.
There are many YouTube videos on how to package your bike in a box, bike bags, etc.. for shipping or airline travel. See one such example below, but use common sense or consult your local bike shop to find the best solution for your situation.
