Going Aero: Some Tips and Tricks for Flying with Your Bike

Bringing your bike overseas can be a daunting prospect for many riders. Airline baggage policies are often labyrinthine, bike disassembly and reassembly require practice and confidence, and the logistics of transporting your bike to and from the airport are often more complex than they would initially appear. This is to say nothing of the dread (tinged with overwhelming excitement, of course!) that comes with watching your trusty steed pass through the oversized baggage doors, as you wonder whether it will arrive safely at its destination. 

And yet, despite these hurdles, the experience for the majority of cyclists is one of surprising ease and efficiency. With a little planning, forethought, and care, the task – while initially overwhelming – can be made manageable. And the reward? Not only the unforgettable experience of cycling abroad, but also an introduction to a mode of travel, and a means of connecting with places and communities, that is both transformative and empowering.

Here, I outline some of my own experiences with overseas touring in 2022 as a prompt for you to think about your own cycling odyssey. It is my hope that by relaying some of the situations and solutions I encountered, you will find it both more feasible and more appealing to take your bike with you on your next journey.

A quick heads up: if you’re looking for tried-and-true bike-packing setup and gear recommendations for your next adventure, we have an excellent primer written by Omafiets staff covering everything from bike selection, to sleep systems, to clothing, cooking gear, tools, and spares. 

Ready to fly? Let’s get started.

1. Bag or Box?

One of the first questions that a cyclist has when contemplating international touring is whether to transport one’s bike in a bag or a box. The best solution for you will depend on two key factors:

1. The type of trip you wish to take. Are you staying primarily at a single location, where you can leave a soft or hard case or post it easily to the next destination? Or are you cycling from one location to another, where a cardboard box which you can discard is a more practical option?
2. Your budget. How much are you willing, or able, to spend on a container? 

Soft Cases: In general, it is best to avoid soft bags made from light canvas or plastic. A rigid container is much more effective at resisting the pressures to which your bike will be subjected in the cargo hold of a plane and during handling. When you are flying long distances with multiple layovers – as is often the case when you are travelling from Australia – the durability of your container is even more important. Some well-constructed, custom-made soft bags will provide great protection, such as Evoc bags, and these can be a good option for single stay tours. Like hard-case boxes, however, they come at a premium, and are not the best option for point-to-point touring; it is difficult and time-consuming to post your bag or box ahead to the next destination.

Hard Cases: Hard-case boxes made from rigid plastic or metal provide excellent protection, and are more transportable than cardboard boxes. However, they are often expensive. They are also heavier, and they don’t leave you with as much space to additional luggage as other cases and containers. This may be an issue if the airline with which you are flying runs on 'piece system' guidelines, which set a cap on the number of baggage items you can check in (you can find more on piece system guidelines in the next section). Finally, like soft bags, hard cases may limit your ability to cycle inter-city: you will be unable to take them with you, unless you decide to post them ahead to your final destination. 

Cardboard Boxes: A third option is to use a cardboard bike box. They’re often free and easy to source! Check in at a bike shop before your flight to see if they have any spares for you (they most likely will), or purchase one if they are on offer from your chosen airline or airport. Qantas are one airline that sell bike boxes from the majority of their Australian terminals. They can be discarded and recycled too, which leaves you free to cycle to other cities without the hassle of posting a bag ahead to your final destination. Their rigid and relatively durable, and can withstand most pressures if they’ve been packed appropriately. 

This isn’t to say they’re foolproof, and not all boxes are created equal! You should check that your box is well-constructed, made of thick or sturdy cardboard, and is in good condition. They require more care and attention to make sure they’re packed appropriately. They're also more vulnerable to the wet and to sharp objects than other packing solutions; they can puncture more easily, potentially allowing items to fall out, especially if they haven't been carefully packed. They're also bulky, which can make transporting them to and from the airport tricky, and bringing them into the maximum dimensions allowed by your chosen airline a little more complicated. In the vast majority of situations, however, they’re a great solution.

See the table summary below for the positives, and the drawbacks, of each container.

2. Navigating Airline Baggage Policies

A second consideration when flying with your bike is the choice of airline. This will be dictated not only by one’s budget, but also by the generosity of an airline’s baggage policy. Researching these policies, however, can be a tricky business. In my experience, I found myself scouring forums relating to different airlines, only to find that the information relayed in them was out of date or simply incorrect. In all instances, it is best to look at the policies listed directly on the airline’s website before you book and shortly before you fly. It is a good idea to email the airline’s customer service representatives for confirmation that the bike can indeed be taken on your chosen flight.

To make things a little easier, I’ve briefly summarised the policies of some major airlines departing Sydney in the table below. I hope it points you in the right direction, and gives you a sense of which airlines are bike-friendly! Please note, however, the following important information (and some hot tips):

• This is intended only as a primer for you to do your own research. You should confirm the policy with the relevant airline before booking, either by looking on their website or by chatting with a customer service representative. 
• The policies listed below reflect economy guidelines. 
• Check the policies of any partner airlines affiliated with your flight. 
• Print out the airline’s bike policies off their website and take them with you to the airport. The airline's attendants may not be across the airline’s bike policy (it’s not every day you get a bike checked in!).
• Many airlines require advance notice if you are planning to bring your bike. In general, it is best practice to confirm with your chosen airline that space is available on your flight. At the very least, print your airlines bike policy, as per the suggestion above.
• Some airlines (e.g. Qatar Airways) will operate with two baggage guidelines: a piece system and a weight system. A piece system is almost always for flights to or from the United States. This places a limit on how many items you can check in, as well as their maximum weight. Most other routes will follow a weight system. A weight system doesn't place limits on the amount of items you can check in, and instead provides a maximum total weight for all your baggage. These guidelines may impact your chosen airline's sport equipment policies. It's always a good idea to double check which guidelines your flight will be subject to.
• Most airlines mandate the following packing directions: 
  • Remove the pedals;
  • Deflate the tyres;
  • Remove the front wheel and attach it to the frame;
  • Fix the handlebars parallel to the frame or to the side of the frame;
  • Place your bike in a protective container (cardboard, hard plastic, custom case etc.).
• Assume that your bike box will be opened for inspection at the airport. If using a cardboard box, having packing tape on-hand at check-in to re-seal the box is a good idea.
• Be sure to thoroughly clean your bike and tyres before you fly to prevent yourself from being held up at quarantine.
• Consider popping an AirTag or other tracking device in your bike container. If your bike is waylaid en-route to your destination, this can be a useful way to keep tabs on its location.
• When you receive your bike at baggage claim, try to check the bike for any damage before leaving the airport. Liability for the airline is limited after you leave the airport, and documentation at this stage is key.
• Most airlines will not take e-bikes. Almost all airlines will refuse to take e-bike batteries over 100wh; these will need to be freighted separately.
• Bike too big to take with you? Consider getting a Brompton ;). 

Airline Bicycle Policies for Economy (as of 15.06.2023)

3. Bike Disassembly and Reassembly

You’ve chosen your airline, and you’ve grabbed the perfect bike box from your favourite local bike shop. With the encouragement of their mechanic, you’ve decided to pack the bike yourself. Nice one! This is an invaluable skill for any cyclist.

The prospect of partially disassembling and reassembling a bike for the first time can be a daunting one. In general, however, the level of disassembly required for travel is relatively minimal, and the steps are intuitive and effective, so long as you are careful and take your time.

There are a number of invaluable resources to guide you in packing your bicycle. The first resource, and the one I have referred to most frequently in my travels, is created by our good friends over at Vivente Bikes. The following video is particularly informative and useful: it outlines some basic principles which can be applied to almost any bike when it is being packed, and the instructions are clear and easy to follow. 

A second useful resource is provided by Park Tool, purveyors of industry-benchmark equipment and advice. The advice they provide is slightly different to that provided by Vivente Bikes, as it is aimed at a broader class of cyclists. Removing your rotors may indeed be the safest option when packing your bike for travel, but disc brake rotor protectors are another good solution. Likewise, while removing a derailleur is the safest option, it is also not the most convenient. If you choose not to remove your derailleur, shifting your derailleur into the lowest gear to bring it as far inboard as possible, and using a rear axle protector that comes with shipped complete bikes (ask your local bike shop), will often work effectively. Moreover, Park Tool point out that you may not need to remove the handlebar stem when packing your bike depending on its dimensions, and so you may not need to make headset bearing adjustments when you reassemble the bike.

In each of these cases, a value judgement should be made about your bike and its safety when packed: what are the contact points of the bike when it is boxed? Is there a way to pad the box with gear to change those contact points, so as to better protect the frame and the delicate componentry attached to it? If not, what will I need to remove and pad those components for peace of mind? Give your box a good shake once you've packed it. If things are rattling around, try redistributing or repacking some of the items to make it as stable as possible, and bundle small items together with larger ones to minimise the risk of parts falling out of any unexpected holes that appear during transit.

When it comes to bike reassembly, Vivente’s resource is again fantastic. It provides clear and concise directions on how to perform effective safety checks without the need for specialised equipment. This is also useful knowledge for everyday cycling, and will help you distinguish normal bike noises and vibrations from those that may indicate a problem.

Below, you can find a list of useful tools for bike disassembly and reassembly:

• Multi-tool with hex keys. There are great tools available with built-in chain-breakers, disc brake pad spreaders, and more. One such tool is the excellent M17 Multitool from Crank brothers.
• Pedal wrench. Don’t get stuck trying to take off or put on your pedals! Great for getting enough leverage and torque. Two great options, depending on your specific pedal type, are the Park Tool 15mm Pedal Wrench or the Park Tool 8mm Hex Wrench. If you’d rather not carry a wrench, another great option are MKS pedals with the Ezy Superior system, a brilliant quick-release mechanism which allows your pedals to be taken off or installed in a flash. Pretty neat!
• Hand pump. You’ll need to get air back into those tyres after they’re deflated, whether at the airport or on the trail. There are some excellent hand pump options on the market, including the Topeak Mini-Morph and the Specialized Air-Tool Switch.
• Disc brake caliper wedge. One characteristic of hydraulic disc brakes is that if they are actuated without the rotor present (i.e. the brake lever is squeezed when your front wheel is removed), the brake will reset and lock. If this happens, you won’t be able to refit the wheel without spreading the disc brake pads. This can be a tricky and time-consuming process, so save yourself the hassle and chuck in a caliper wedge as soon as you remove the wheel. Give your local bike shop a buzz to see if they have any for sale, or any spares. 
• Front fork block. The fork is one of the more delicate components of your bike, and if it is subject to significant pressure it can be bent. To minimise this risk, it’s a good idea to chuck a front fork block where the axle is fitted. Vivente’s article has good tips on how to do this. You can buy one online, or improvise one out of a rigid material – a piece of piping, a wooden block, or even a rigid postal tube, cut to size – if you're having trouble sourcing one.
• Front disc rotor protector. If you’re not removing your rotors, this is a great option to protect your bike. They generally come shipped with new bikes, and your local bike shop may have some spare.
• Rear axle protector. Like the front disc rotor protector, these are single-use plastic protectors that can minimise the risk of your rear derailleur being bent in transit if you choose not to remove it. Again, it is best to check the contact points of your bike in the box, and pack your box to prevent compression from affecting the frame or any componentry. 
• Headset spacers. If you’re removing your handlebar stem, you’ll want some way of making up for the spacing provided by the stem. Having a few extra headset spacers on hand is a great way to do this. They can be purchased either online or at your local bike shop. You can also improvise one out of some cardboard or tubing!

4. Time to fly!

• Riding to or from the Airport. The most adventurous solution. Airports are often located on the outskirts of cities (Sydney is an outlier in this regard), and as such connecting roads may be high-traffic and high-speed, but with a little research you can find some great cycling routes. If riding to the airport, be sure to take most packing materials with you, such as tape and bubble wrap, and ensure that a bike box is indeed able to be purchased from check-in. Give yourself plenty of time to pack the bike, and find somewhere quiet and out of the way to assemble or disassemble your bike. 
• Public transport. Trains are often the best solution here. However, note that there may be restrictions on luggage size, including packed bikes, for different public transit systems and between certain hours. If you're carrying multiple bags or have a flight around rush-hour, this may be a trickier option. However, it is often very efficient and cost-effective.
• Family and friends. The best solution! Who doesn't want to be met or seen off at the airport by loved ones?
• Taxi. A minivan or SUV taxi will often be able to fold seats down for you. They should be booked in advance, especially if you're going to the airport, but if you're arriving at an airport there will often be plenty around.
• UberXL. UberXL cars can often fold down their seats to fit larger items.