Airline Mountain Bike Travel: Preparation Tips

how to travel airline mountain bike

Travelling with a mountain bike can be a daunting task, but with some careful planning and packing, you can be cruising down dusty singletracks in no time. All airlines require you to pack your bike before flying and it's important to know each airline's policy and fees to avoid problems at the check-in desk.

Firstly, you'll need to disassemble your bike, removing the wheels, pedals, bars and, in some cases, the rear derailleur. You'll also need to deflate your tyres. Then, you'll need to pack your bike in a bike bag or box. Cardboard boxes are a cheap option, but they offer little protection and may not meet some airlines' requirements. A dedicated bike bag or box is a better option, offering more security, protection and storage for your bike.

When choosing an airline, consider that some are more bike-friendly than others. Some airlines charge a fee for taking your bike on the plane, while others include it in your normal baggage allowance. It's worth checking if an upgrade to a higher class with a more generous baggage allowance is cheaper overall.

Finally, give yourself plenty of time to pack your bike and always practice packing it before your trip. This will ensure you know how much your bike and box/bag combo weighs and that you have all the tools you need to reassemble your bike when you reach your destination.

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Choosing a bag or box

When taking your mountain bike on a plane, you'll need to pack it in something—usually a cardboard bicycle box, a hard-shell bike case, or a soft-sided bike bag. Each option has its pros and cons.

Cardboard Box

Cardboard boxes are cheap and good for one-way trips. You can usually get them for free from your local bike shop. However, they don't offer much protection and are prone to damage, especially in wet conditions. They are also large and ungainly, and most airlines won't insure or cover any damage to bikes packed in cardboard boxes.

Soft-Sided Bike Bag

Soft-sided bike bags are generally smaller and easier to transport than cardboard boxes. They usually have straps and wheels that make them easy to move around. However, they are more expensive, ranging from about $400–$600 USD, and many airlines require a liability release for bikes packed in soft-sided bags. They can also be challenging to pack and often require extra padding.

Hard-Sided Bike Case

Hard-sided cases offer the most protection for your bike, but they are also the most expensive option. They are heavy and awkward to transport, and they will almost always result in overweight fees. They are also quite obvious, so if your airline charges a bike-specific fee, there's no avoiding it when using a hard case.

Hybrid Options

There are also hybrid options that combine the best of both worlds. For example, the Thule RoundTrip Pro XT falls into the "not-quite-a-bike-bag" category. It's a softshell but has some structural implants that provide extra protection for your bike. Another example is the Scicon AeroComfort 3.0, which has a soft exterior but houses a metal structure to which you fasten your frame. This option requires very little disassembly and leaves plenty of room for extra kit.

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Disassembling your bike

  • Remove both pedals.
  • Remove the stem faceplate and handlebars.
  • Partially deflate the tires, especially if they are tubeless.
  • Remove both wheels.

For added security, you may also want to:

  • Remove the rear derailleur.
  • Remove the front and rear rotors, as these can get bent during transit.
  • Remove the seat post, if your bike doesn't fit in the bike bag or box with it attached.
  • Deflate the front and rear shocks, if you have a mountain bike.

If it is your first time packing your bike for air travel, give yourself plenty of time. It is recommended that you spend time watching YouTube videos and allow 1-2 hours for the packing process. Alternatively, bike shops will pack your bike for you for a small fee.

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Packing your bike

Packing your mountain bike for a flight can be a stressful experience, but with some careful preparation, you can ensure your bike arrives safely at your destination. Here are some detailed instructions on how to pack your mountain bike:

Disassemble the Bike:

  • Shift into the hardest gear to make it easier to remove the rear wheel and protect your derailleur.
  • Remove the pedals using a pedal wrench.
  • Take off the handlebars and secure them vertically on the non-drivetrain side of the bike. Use electrical tape or ties to secure them.
  • If you have Di2 cables, use the Di2 remover tool to unplug them from the junction box.
  • Loosen the seat post bolt and remove the seat post from the frame. If you have a dropper post, you may not need to remove it.
  • Remove the wheels. If your bike has thru axles, remove them as well.

Protect Brake Calipers and Remove Rotors:

  • Place spacers or a piece of cardboard in your brake calipers to prevent the brake levers from being activated during transport.
  • Remove the brake rotors to prevent them from bending. Place them in a plastic bag with cardboard separators to avoid damage and reduce noise.

Cushion and Secure Derailleur:

  • Remove the derailleur and cushion it with a towel, bubble wrap, or a hollowed-out Styrofoam block. Secure it to the bike frame with electrical tape.
  • Secure the chain by wrapping it in bubble wrap or placing it in a chain bag.

Final Steps:

  • Pack all the removed components securely in your bike bag or box. Don't let them float around and potentially scratch your bike.
  • Deflate your tires partially. This is usually required by airlines, and it will make packing easier.
  • Use pool noodles, bubble wrap, or foam to cushion the frame and other exposed parts.
  • Make sure your name, home address, and destination address are clearly marked on the bike and the luggage.

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Weighing your bike

When weighing your bike, make sure to include the weight of the packaging and any additional protection you use. Bubble wrap, pipe insulation, or pool noodles are great options for adding extra protection to your bike. You can also use cardboard boxes, but keep in mind that they are prone to damage and may not provide sufficient protection for your bike. Soft-sided bike bags and hard-shell cases are also available, with the former being easier to transport and the latter offering more protection.

It's important to note that different airlines have different weight limits and fee structures. Some airlines may waive overweight fees for bikes under a certain weight, while others may charge a flat fee for bikes regardless of weight. Additionally, the weight limit may vary depending on the class you are flying in. Therefore, it is crucial to check the specific policies of the airline you plan to fly with.

In addition to weight limits, airlines also have size restrictions for checked baggage. Most airlines consider a bike to be oversized if it exceeds certain linear dimensions (length + width + height). These limits vary by airline, but they typically range from 62" to 158". If your bike exceeds these limits, you may incur additional oversize fees. To avoid this, consider removing the handlebars, pedals, wheels, and other components to make your bike more compact.

When preparing your mountain bike for travel, pay close attention to the weight of your bike and any additional gear you pack with it. Adding extra kit and equipment can result in expensive overweight penalties. Additionally, mountain bikes tend to be bulkier than road or gravel bikes, so ensure your travel case or bag is large enough to accommodate it. If your bike still doesn't fit, you may need to let some air out of your suspension to reduce its height.

In conclusion, weighing your bike is crucial when preparing to fly with it. By considering the weight of your bike and the packaging, you can avoid overweight fees and ensure a smooth travelling experience. Remember to check your airline's specific weight and size restrictions and pack your bike accordingly. Safe travels!

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Preparing for reassembly

Before you set off on your trip, it's important to prepare for the moment when you will be putting your mountain bike back together. Here are some steps to follow to make the reassembly process smoother:

  • Keep Track of Dismantled Parts: As you disassemble your bike, keep a record of the order in which you remove components. This will help you remember the correct sequence for reassembly. Taking photos of each step can be a useful visual guide.
  • Label and Organise Parts: Use plastic bags or containers to organise the various parts of your bike, such as pedals, handlebars, and wheels. Label each bag or container with the name of the component and any relevant details, such as left or right side. This will make it easier to locate and identify parts during reassembly.
  • Store Tools and Accessories: Gather all the necessary tools and accessories you will need for reassembly, such as Allen keys, wrenches, and any specific tools required for your bike model. Keep them together in a tool bag or box for easy access.
  • Practice Reassembly: If you have time before your trip, consider practicing reassembling your bike. This will help you familiarise yourself with the process and identify any issues or missing parts ahead of time.
  • Bring Extra Parts: It's always a good idea to bring some spare parts, especially if you're travelling to a remote location. Having extra components like brake pads, derailleur hangers, and tubes can save you from being stranded with a non-functional bike.
  • Print Instruction Manuals: If you need guidance during reassembly, print relevant pages from the instruction manual or seek online resources that you can access during your trip. Having a physical copy ensures you're not reliant on stable internet connections when you need guidance.
  • Clean Your Bike: Before packing your bike, give it a thorough cleaning. This will make the reassembly process more pleasant and help maintain the condition of your bike and its components.
  • Prepare for Adjustments: Keep in mind that you may need to make adjustments to your bike's settings, such as suspension and gear shifts, once you've reassembled it. Have the necessary tools and knowledge ready to fine-tune your bike to your preferred settings.
  • Seek Professional Help: If you're unsure about any part of the reassembly process, don't hesitate to seek advice from a professional bike mechanic or a knowledgeable friend. They can guide you through the process and ensure your bike is properly reassembled.
  • Allow Sufficient Time: Reassembling your mountain bike may take some time, especially if you're doing it for the first time. Plan your schedule accordingly and allow enough time for reassembly, so you're not rushed or stressed during the process.

By following these steps and preparing for reassembly in advance, you'll be able to get your mountain bike up and running smoothly at your destination, ensuring a more enjoyable riding experience during your trip.

Frequently asked questions

You will need to disassemble your bike and pack it in a bike bag or box. You can use a cardboard box, but it's recommended to use a hard-shell box or a soft-sided bag for added protection. Make sure to wrap your bike in bubble wrap or other protective materials, and deflate your tires to avoid damage.

The weight and size restrictions vary by airline, but most airlines require your bike and its container to be under a certain weight and size limit, typically around 50 lbs (23 kg) and 62 linear inches (158 cm). If your bike exceeds these limits, you may have to pay additional fees.

Yes, you will need to remove the pedals and wheels from your mountain bike when packing it for air travel. You may also need to remove the handlebars, stem, and other components, depending on the size of your bike and the container you are using.

Some airlines require you to make a reservation for your bike in advance. It is also recommended to get insurance for your bike, as airlines may not cover damage that occurs during transit. Additionally, you may need to sign a liability release form when travelling with a bicycle.

Here are some tips for flying with a mountain bike:

- Shop around for lower baggage fees, as they can vary significantly between airlines.

- Weigh your bike and its container before going to the airport to ensure you are within the weight limit.

- Be cautious of long layovers, as you may need to collect your bike during layovers over 12 hours.

- Use zip ties to secure your bike and prevent loose parts from falling off.

- Don't panic if your bike doesn't show up immediately at your destination; it may have missed your connecting flight and will likely arrive on the next flight.

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