How To Pack Your Bike For Air Travel (And Fly For $35 Total!)

[@jamiegrant8764]

Love the videos. I have done many long haul flights with my bike from the Scottish Highlands to Phoenix AZ and I'd say take the rear derailleur off completely and wrap it up and either tape or loosely cable tie it onto the chainstay as the baggage handlers could load other bags on top of your box/bike bag or get one of those old mtb derailleur protectors and put that on. You also get a disc pad spacer that slips between the pads to save you removing them. If you take the wheels off put a spacer in between the dropouts on the forks and rear stays just incase they get squashed. Deflate your tyres to least half pressure as well as airlines like that done. Depending on the size of your box/bag or if you have removed both wheels you can get away with just turning the bars 90° then loosen the bar bolts and rotate the bars downwards. I'd also recommend cleaning your bike thoroughly as dirt can carry bugs that may not be present in another state or country. No Co2 canisters either as that is usually not allowed. If you ever get the chance come do the Hebridean way and the North Coast 500 in the Highlands.

[@KevDoes]

I love the tips Jamie! Thank you!

[@shinhochulp]

I would actually unbolt the rear derailer altogether. Wrap it in some bubble wrap and tape it to the chainstay. Or at least carry an extra derailer hanger with you.

[@KevDoes]

That's a good call Paul! I may take you up on that on the next trip

[@ronmann802]

Thank you thank you... So kind of you to show how's to be done properly. Biiiiiigggg help

[@KevDoes]

My pleasure Ron! This is what has worked for me, hope it helps you!

[@perserventia]

Thanks. Good video !m heading to Colo Springs tomorrow for 2 day trip with my daughter there.

[@KevDoes]

Enjoy it! That’s amazing!

[@ezradee2967]

Thanks for the video! bouta pack up my bike to do Seattle to New York.

[@KevDoes]

Whoa! That’s an amazing trip! Congratulations!!

[@roastawk]

You can make tube protectors like those seen at 4:38 from foam pipe insulation obtained from a hardware store. Two 6 foot pieces (one small diameter, one medium) will provide more than you could ever need for just a few dollars. I also recommend buying axle spacer inserts if you don't have thru axles. Old hubs or wooden dowels from the hardware store will also do. They will save you from a bent or broken fork. Also grease the pedal threads to make future assembly and disassembly easier.

[@KevDoes]

All great tips Frank! Thank you!

[@newttella1043]

I would leave the brake pads in. Fold together a scrap piece of paper enough times to snugly slide in between the brake pads. If you take the pads out, just many more pieces to lose or misplace. I would also just unscrew the derailleur from the frame and tape it to the chainstay. Derailleurs are tough but bending or breaking the drop out would be maddening. Great pack job overall!

[@KevDoes]

Great tips! I appreciate you teaching me something new!

[@paulverweij6348]

I use some ziptyes to fix the realweel on the cardbox few small holes in the back of the box lower bike in and push the ziptye from outside around rim and out again, it wont slip to the front any more (sturdy bike box is needed :P) and remove the rear derailer fix it to the rear end of the frame prevents also lots of dmg.

[@KevDoes]

That's a good idea Paul! Really glad it works!

[@FollowThomas]

Thanks for detailed step by step guide, it really helps.

[@KevDoes]

My pleasure! So glad it could help!

[@johnmanuel7561]

Great video Kev! I learned the hard way in not using extra padding and received a cracked frame. I’m looking forward to my next flight and protecting my bike to the Max to prevent damage.

[@KevDoes]

Ah that would be the worst. Bummer to hear that happened to you, but glad you know what to do for the next!

[@WanderingEyeOutdoorAdventures]

Thanks for the tips Kev! There is however a much easier way to do the brakes. Each type of brakes makes a spacer that you insert between your brake pads to take up the space the rotor would normally occupy. That little yellow block is normally used for brake bleeds. The spacers are just much quicker than removing and replacing the brake pads every time and less things to lose. If you ask your LBS they should have the spacers/shims that you need for your specific brakes. Cheers

[@KevDoes]

You are 100% correct! That’s going to make things so much easier! Thank you

[@WanderingEyeOutdoorAdventures]

@@KevDoes my pleasure!

[@raven_shp]

Thank you for the explanation. Very useful for a first-time bikepacker! ;)

[@KevDoes]

My pleasure! So glad it could help!

[@mhargler]

This was really helpful! Thanks for the breakdown.

[@KevDoes]

My pleasure! Glad you found it useful!

[@chrislonsberry1974]

Great info Kevin! I didn’t know any airline would take a bike on a flight for less than a $150!

[@KevDoes]

Yeah Chris! Most airlines are starting to give more options as long as your bike weighs less than a certain amount and fits inside a certain size box!

[@dtmchemistry5279]

Thanks for the video!! I am going to Florida on the south west coast. First time flying my bike. I am flying South West any pointers for that air line?

[@KevDoes]

I have never flown with southwest, but I know they give you two free checked bags so I would look into seeing if one of those checked bags can be a bike because you may then be able to fly for free! I would also look into their specifications for the size and weight of the box in order to avoid an oversized or overweight fee!

[@Eric_Tennant]

T-1 Week. I'm going for a 400 miles ride in Arizona mountains. Leaving from front door so no box is needed. Just need my sleep system, cameras for YouTubing, drone also for YouTubing, batteries and my e-bike.

[@KevDoes]

That would be so fun! Leaving from your house would be great!

[@Eric_Tennant]

@@KevDoes At some point I will have to ride outside of Arizona, but still I can make bigger loops. Seem we both do the same type of videos. Somewhat the same anyhow. Bike adventure videos. I'm just using electric right now. That and I'm at the bottom of the sub ranking and good old Ryan at more of the top for this category.

[@Foti5]

how about stove and tent ? can put together on with bikes ?

[@KevDoes]

Space wise sure, but weight starts to be the concern there

[@RecapturingLife]

Thank you for this! I’m still thinking about if I’ll take the train or the plane. I’m not sure yet. The cross country train seems like a prettier way to get home from a cross country bike trip but it will take significantly longer. It’s good to know the plane isn’t a complicated or expensive process. Do you feel safe on the planes? Is there still social distancing going on? Again thanks for taking the time to share this information.

[@KevDoes]

I know on Delta they are still keeping the middle seats open, but it is definitely sketchy on some of the planes. A cross country train trip would be so fun!

[@frankbikes2416]

Super helpful! Thanks!

[@KevDoes]

My pleasure Frank!

[@LightningBolt700]

Hey kev, when air traveling with a bike and you make connecting flights, what is the best way to ensure that your bike arrives at the final destination without being stolen? Do you put insurance protection from the airline on your bike? Thanks !

[@KevDoes]

That's a great question that I haven't ever had to deal with. Even when flying with regular checked luggage that has a connecting flight I get a little nervous so I don't have a good answer for you unfortunately

[@rick_1968]

what do you do with the box on the other side of your flight, if you don't need it anymore and you've put the bike back together at the airport?

[@KevDoes]

On the way to my adventure I have done two things: either recycled the box at the airport or kept the box in my friend's van! Otherwise I keep it at my house!

[@noelmcfarlane1677]

Hi Jamie, I've flown with my bike literally hundreds of times. Rarely in the USA due to the cost. Technically I'd change a few things in your method but most are addressed in comments already. But the biggie is the carton size. You mention at the very end as 62" girth for AA. But the carton you are using in the vid is way more than 62". I reckon it is 10" x 30" x 55". 95" total. I've just checked the AA site on this issue and unfortunately can't quite figure it out. So have you actually fronted up at an AA counter in the US with this size carton and if so what was the charge?

[@KevDoes]

is this addressed to me? Yes this is how I flew the bike on my trip. The charge was either $30 or $35 just like a checked bag would be. On most airlines as long as it is in a bike box and under 50 lbs they aren't too strict on sizes

[@LuisBecerra79]

I don’t even have a 🚴, but taking a lot of notes 🤓.

[@KevDoes]

Well you have all of the tools for when you get a bike!