Folding Bikes - Looking for a Bulletproof Folder

I travel all over the place with my folding bike and the thing is really taking a beating! The reflectors are broken off, the rack is cracked and the frame is even bent in a spot. It’s not that I’m a hard rider; it’s just that it gets thrown around by baggage handlers and stacked under hundreds of pounds of luggage. With the way I travel, a hard case is not an option so I need something that will stand up to a beating. I would prefer something with multiple speeds but not a derailleur. Any advice is appreciated! If you want to check out my travels, go to: http://www.foldingbikedestinations.blogspot.com/

a brompton will fit in a standard suitcase. so get a hard shell samsonite and get a brompton

and
it also when it is folded up a brommie is more
immune to damage from the suitcase being stacked and squeezed

brompton. been all over the planet with it. zero issues

travering with a dahon is a breeze.
just pack it up into any normal suitcase and you a good to go

brompton. been all over the planet with it. zero issues [2]

a brompton will fit in a standard suitcase. so get a hard shell samsonite and get brompton. been all over the planet with it. zero issues

There's no current Samsonite suitcase that the brompton will fit into, as far as I know, unless you consider significant disassembly. The Delsey Axiom was a discovery another forum member made (search threads) being the only (that I've read of) case that the brompton will fit in. I have a flite 31 (Samsonite's biggest I think) and it won't fit in there. I have the Axiom and it does, but it's aided by having the telescoping seatpost so you can pull out the seat and only the nub is present on top. Physical disassembly, as you know, of the brompton can take some time.

But guys, the OP said "no hard case":


... With the way I travel, a hard case is not an option so I need something that will stand up to a beating....

and that's a thing I can understand very well, who wants to carry a hard case when biking around? Still I would double: brompton.
Protect the rear roller wheel stays with cardboard, change the sticking out shifters for a grip shifter, change perhaps (not sure of that) the plastic chain-tensioner for a merc alu, loosen the brakelevers and for the rest a soft case should do.

I'm wondering about the "no hard case" limitation. Do you mean that you don't want an extra case just for the bike. That you just want to pack the bike in the same luggage as your clothing? Or that you just want to check the bike in without a bag or anything covering it up?

--sam

travering with a dahon is a breeze.
just pack it up into any normal suitcase and you a good to go

Having packed a Dahon P8 series for international travel many times, I may assure you: not a breeze (http://www.gaerlan.com/dahon/pack.htm).

Bikes that are a breeze to pack: Brompton (of course), Tikit, certain other Bike Fridays, Dahon Curve.

First, if your frame is already bent then you need to fix or replace the frame ASAP. A bent frame is likely to fail, in which case you will end up kissing pavement.

Second, unfortunately there is no bike that can handle multiple trips in airplane baggage in a soft bag or soft case without sustaining some damage. Using an internal hub does remove one item from the equation, but plenty of other parts can get damaged -- as your bent frame already proves. ;) The best you can do is find some sort of padded bag and protect the components as best as possible.

The only other changes I could possibly think of is to pick up a relatively cheap folder like a Downtube. DT's have very solid frames and cheap but standard parts and a few models with internal hubs (i.e. don't use derailleurs). That way, you have the budget to fix or replace it at will.

By the way, it's a bit unclear on why a hard case isn't an option. You probably have good reasons for this, but it's just not obvious.

...By the way, it's a bit unclear on why a hard case isn't an option. You probably have good reasons for this, but it's just not obvious.
I can not speak for the OP of course. How I imagine myself to travel when combined airline and bike travel is with all my gear on the bike (panniers, small backpack) while riding. Imagine you fly somewhere, bike directly out of the airport to your next hostel or to a camping somewhere. You stay not at one hotel and do bike trips from there but do a round trip including rail travel and fly back from another destination. What are you doing with a hard suitcase then? Okay Bike Friday trailer suitcase is an option but riding with a trailer is not everyone's cup of tea, mine definitely not.

I'm wondering about the "no hard case" limitation.... That you just want to pack the bike in the same luggage as your clothing?...--sam I would like to have a kind of soft case (or ultra light rimowa like policarbonate bag) where I can put the bike and plastic bagged clothes - which then give some protection - and which splits in kind of two panniers after the air travel.

Would it be possible to use a hard case, but store the case in a locker while traveling?

Somnatash's post was exactly right! I fly to my destination, then I unfold my bike and have to take the case with me. You can see why it would be dificult to strap a huge suitcase on my back and bike through the city. With my bike bag, I simply fold it up and put it in my backpack or paniers. The downside of course is that the bike takes a beating in transport. So far, I'm hearing a lot of Brompton, Anyone else feel their bike would be up to the challenge?

Lalato, great idea, but there are many destinations where that isn,t an option. Last week I flew into Parowan Utah. A tiny little town. No lockers, not even an airport terminal and no place to store a bag. Really a softshell case is the best option for me.

Any advice is appreciated!

http://www.foldingbikedestinations.blogspot.com/ (http://www.foldingbikedestinations.blogspot.com/)

I thought that the Brompton hard case was pretty small in its own right. From a quick internet search (http://www.wcfanshop.com/servlet/the-179/Brompton-Bike-Travel-Suitcase%2C/Detail), it is pretty expensive. However, it looks like it would strap down pretty easily onto the rear rack or perhaps into a large front bag.

The linked webpage also reads that the case is 23 pounds. That makes the combination of the two awfully close to the common oversize/overweight limit (50 pounds).

Somnatash's post was exactly right! I fly to my destination, then I unfold my bike and have to take the case with me. You can see why it would be dificult to strap a huge suitcase on my back and bike through the city. With my bike bag, I simply fold it up and put it in my backpack or paniers. The downside of course is that the bike takes a beating in transport. So far, I'm hearing a lot of Brompton, Anyone else feel their bike would be up to the challenge?

Lalato, great idea, but there are many destinations where that isn,t an option. Last week I flew into Parowan Utah. A tiny little town. No lockers, not even an airport terminal and no place to store a bag. Really a softshell case is the best option for me.

Any advice is appreciated!

Downtube Mini w/Sturmey 8spd! .. strong frame.. strong 16" wheels.. inside fold handlepost.. no dangly bits .. comfortable ride... mostly non-proprietary parts that count.. not expensive.

Final question about a hard case... how about the option of a hard case that converts into a bike trailer? Just wondering...

As for bulletproof bike options... Personally, I think you need the least expensive bike you can get that fits your needs. I believe the suggestion for a Downtube is probably the best. If something drastic happens to it, you can get a replacement for relatively small amount of money. Most of the parts are pretty standard so if something breaks you can get it fixed more easily.

--sam

Downtube Mini w/Sturmey 8spd! .. strong frame.. strong 16" wheels.. inside fold handlepost.. no dangly bits .. comfortable ride... mostly non-proprietary parts that count.. not expensive.I have not seen the mini in person and sure from posts here, it must be a gorgeous little bike, certainly worth a close look for the task...but from pics I get the impression that "minis more sticking out parts" when folded are in more danger...no big difference. See in this post the bikes are in pictures compared (here the handlebar in outside, was the hinge turned for handlebar inside?):
http://www.bikeforums.net/showpost.php?p=2897669&postcount=6

Yes, I believe the 2009 Downtube Mini has the handlebar folding inside.

http://www.downtube.com/images/2009_Bikes/mini_Folded_small.jpg

--sam

Somnatash's post was exactly right! I fly to my destination, then I unfold my bike and have to take the case with me. You can see why it would be dificult to strap a huge suitcase on my back and bike through the city. With my bike bag, I simply fold it up and put it in my backpack or paniers. The downside of course is that the bike takes a beating in transport. So far, I'm hearing a lot of Brompton, Anyone else feel their bike would be up to the challenge?

If we're talking taking bikes on airplanes, the company to beat is Bike Friday. All of their bikes were specifically designed to go onto airplanes. Here's a video of Packing the Tikit (http://www.youtube.com/watch?v=6m29V31VgfI) in a standard Samsonite oyster shell suitcase. Bike Friday's bikes can also be set up to tow their own suitcases (http://bikeportland.org/2007/03/02/my-tikit-to-san-jose/).

Somnatash's post was exactly right! I fly to my destination, then I unfold my bike and have to take the case with me....
I figured as much. The alternative, in case it isn't obvious, is to take a taxi to a hotel and have them hold the hard case for you until you get back. Assuming you're doing a round-trip flight, of course.

I know it's a different method, but unfortunately without a hard case it's possible that you may arrive at your destination with, for example, a busted spoke. If that's the case, you're not cycling out of the airport anyway. ;)

I will say, though, that even a hard-shell case doesn't offer perfect protection. You'd have to use compression members and hope that if the TSA opens the suitcase, they put things back the way you packed 'em.

But let's face it.... At this point, both common sense and experience is clear that any bag that you can carry with you on your tour is not going to offer very good protection. Perhaps you could learn how to deal with the occasional damage, so it doesn't cause major issues? E.g. take as many classes as possible on bike maintenance, thoroughly inspect your bike after each flight, and bring spare parts & tools with you. It's a handy skill set to have anyway if you tour a lot.

Bike Friday's bikes can also be set up to tow their own suitcases (http://bikeportland.org/2007/03/02/my-tikit-to-san-jose/).

FWIW, any bike that fits in a hardshell case can do this. Bike Friday just has all the pieces in one place at their website.

I have traveled with my Swift in a hardshell Samsonite case, and it works fine. Putting it back together once I take it out of the case is a little annoying, but that's because I suck at bike mechanicking.

So it sounds like someone needs to invent a folding hard case. :p

So it sounds like someone needs to invent a folding hard case. :p

Yes please: ultra light and transformable to 2-3 bike-panniers :)

A "folding case" disposable at destinations and comparatively easy to get again could be the cardboard box for TV/microwave/folding bike/..

It would be nice if someone made a bike bag with plastic tile-like pannels so it could still be folded and put in a backpack and give more protection than a regular soft-shell bike bag.

http://www.foldingbikedestinations.blogspot.com/ (http://www.foldingbikedestinations.blogspot.com/)

There's no current Samsonite suitcase that the brompton will fit into, as far as I know, unless you consider significant disassembly. The Delsey Axiom was a discovery another forum member made (search threads) being the only (that I've read of) case that the brompton will fit in. I have a flite 31 (Samsonite's biggest I think) and it won't fit in there. I have the Axiom and it does, but it's aided by having the telescoping seatpost so you can pull out the seat and only the nub is present on top. Physical disassembly, as you know, of the brompton can take some time.

well I have a hard shell samsonite and all i do is pop the brompton saddle off and it all
fits in so if they don't sell one that fits anymore then don't go with samsonite

Final question about a hard case... how about the option of a hard case that converts into a bike trailer? Just wondering...

As for bulletproof bike options... Personally, I think you need the least expensive bike you can get that fits your needs. I believe the suggestion for a Downtube is probably the best. If something drastic happens to it, you can get a replacement for relatively small amount of money. Most of the parts are pretty standard so if something breaks you can get it fixed more easily.

--sam


bromton. my hard case can convert to a trailer and be towed behind the brommie. all parts fit inside

bromton. my hard case can convert to a trailer and be towed behind the brommie. all parts fit inside

You did the mod yourself? Or is it sold that way?

taking a different tack, a mini is very solidly put together - and, I think, comprises more standard/cheap (costwise?) parts ? So if shipping using a softbag/bubblewrap combo, eaiser to repair? Just a thought. But for touring, despite Sammy's example, not sure how much you can carry on it...

well I have a hard shell samsonite and all i do is pop the brompton saddle off and it all
fits in so if they don't sell one that fits anymore then don't go with samsonite

Samsonite has a lot of suitcases over many many years. It's important to specify which exactly.

So it sounds like someone needs to invent a folding hard case. :p

+1.

I picture a tough nylon bag similar to a garment bag, tailored specifically to the bike at hand. You'd have a little padding at the right spots inside the bike, and a combination of small hard protective shell bits and padding around the outside, all sewn into the shell of the bag; and pockets for the parts you remove. Ideally you remove only the seatpost. The whole thing should zip up into a tight package hardly any bigger than the bike.

Best bike for this purpose, in my opinion, is the Downtube Mini; but by now I'm sure you all know how biased I am.

I wonder if the staff of clever designers at VeloChocolate could be persuaded to take up the challenge....

Sounds like a custom case may definitely be the way to go. I think I'm still going to need a new bike, and I would like one less prone to damage. I know nothing can put up to the abuse of airline travel forever, but some bikes are more susceptible to damage than others. I was just checking out Bigfish, that's a pretty unique fold, everything tucks in and no derailleur. I know it's a pretty new bike, anyone have any experience with them?

http://www.foldingbikedestinations.blogspot.com/

Thee haven't been any review threads here on the Big Fish. The bike did make an appearance at the Smithfield Nocturne so it's possible somebody took it for a spin there. The folded size seems pretty big to my eyes. I think you would want something that folds smaller.

--sam

You did the mod yourself? Or is it sold that way?

made it myself. took some aluminum box parts and some bolts and straps
and old bikes parts and basically
copied what i saw in brompton pictures of a trailer they used to sell.

one long axle bolt longer than the width of the case, cut in half
when installed i screw them together with a long binder bolt

small metal wagon wheels and nuts and washers

cut 2 small holes on the side of the case, stick axle through, connect wheels

3 pieces of alumimum box makes an arm that straps to the seatpost of the brommie.

---
when I fold up the bike and stuff in case, I take all the parts and stick them into
the spaces left over in the case. it is a tight fit but it all tetris's in there fine.

I never use it. just built it and it turns out I just use the brommie bag all the
time and don't need the trailer. but if I did need a trailer i have one. I travel
with all the trailer parts though...just in case I need it

Oversized soft case + cardboard + duck tape = Soft case with tough liner.

Recycle the liner at your destination and carry the folded case on tour. Immediately prior to your flight home locate more cardboard (possibly from the same place you recycled the original liner) and make another liner. 2-3 layers of cardboard should be enough.

I like the idea of beefing up my bike bag for more protection. However, I travel with it at least a couple of times a month so I would feel a little guilty about throwing away a bunch of boxes and duct tape every time I travel. Also, seeing how I travel so often, it would be worth it to me to find a more permanent solution as opposed to trying to round up cardboard boxes every time I travel. I'm sure I could have a custom bag made, but I'm also sure I don't want to know how much that would cost.

http://foldingbikedestinations.blogspot.com/

I think your best bet is a Bike Friday style hard case that converts into a trailer. I know you don't really want a hard case, but I think it's the best option for your desired use.

--sam

How about some stiff plastic panels that would double as internal pannier back walls? The panels could be strapped/cable-tied over the more vulnerable bits, and at the destination undo the zip ties and stick the panels into the panniers as back walls. Re-usable cable ties will eliminate waste.

I like Jur's recommendation. You could use pieces of coroplast. It's the stuff often used for yard signs. It's tough, lightweight, and weatherproof.

And you could use velcro cable ties to strap things together.

Somnatash's post was exactly right! I fly to my destination, then I unfold my bike and have to take the case with me. You can see why it would be dificult to strap a huge suitcase on my back and bike through the city. With my bike bag, I simply fold it up and put it in my backpack or paniers. The downside of course is that the bike takes a beating in transport. So far, I'm hearing a lot of Brompton, Anyone else feel their bike would be up to the challenge?

Lalato, great idea, but there are many destinations where that isn,t an option. Last week I flew into Parowan Utah. A tiny little town. No lockers, not even an airport terminal and no place to store a bag. Really a softshell case is the best option for me.

Any advice is appreciated!

http://www.foldingbikedestinations.blogspot.com/ (http://www.foldingbikedestinations.blogspot.com/)

As Lalato says...$100, you can get a trailer and tow the hardshell behind you wherever you go.

Proprietary hard cases just end up being expensive damaged cases you can't repair and occupy a lot of space interim. Using common items like bubblewrap and cardboard, plastic, rubber, you repair and use local materials as you roam, learning from the damage and evolving your skills. The hardcases add significant weight, they add to the force of impact, anything which looks strong will be more heavily abused by the baggage handlers. If you';re concerned about the environment, use as your packaging material the discarded items at the back of any store, probably only you need to buy is gaffer tape, all you're doing is temporarily redeploying some waste products before they go to recycling/landfill, as bike packaging.

At the end of the day, the best product is one you can make with hands & brain, which goes everywhere with you. More useful than a cracked case and no skills.

The Bromptons are pretty tough, each time I flew them, I honed my packaging skills. Practice packing at home and roll them down an incline to see what catches.

The Bromptons are pretty tough, each time I flew them, I honed my packaging skills. Practice packing at home and roll them down an incline to see what catches.

I am hesitant to get a new bike for exactly that reason. I would like to get most of the learning out of my system so that I'm not learning how to pack and travel with a new bike.

http://foldingbikedestinations.blogspot.com/

Tell me more! I have a Dahon Curve and I am looking for suitable bikecases or bikeable suitcases. For air travel and then rental car, a softer (inflatable ?) suitcase that could be flattened or broken down would be sweet.

Randy

Striegel's coroplast idea sounds good. Not only will there be tons of discarded political signs available shortly for free here in the US, but coroplast has enough rigidity to repurpose for other pieces of kit at your destination. Panniers, shelter floor or roof, etc. I've seen ultralight backpacks made from it, and several amazing streamliner fairings. Of course some projects take more than a little talent and quite a bit of work...

http://img357.imageshack.us/img357/5347/pict2160dt7.jpg

Still, panniers or shelter floor/roof are pretty easy.

I've come to the conclusion that I'm either going to have to go with a custom bag, or a trailer. I would still like to get a bike that is less prone to getting dammaged. I keep hearing a lot of Brompton. Any other bike owners out ther who are impressed with their folder?

http://foldingbikedestinations.blogspot.com/ (http://foldingbikedestinations.blogspot.com/)

I like the idea of beefing up my bike bag for more protection. However, I travel with it at least a couple of times a month so I would feel a little guilty about throwing away a bunch of boxes and duct tape every time I travel. Also, seeing how I travel so often, it would be worth it to me to find a more permanent solution as opposed to trying to round up cardboard boxes every time I travel. I'm sure I could have a custom bag made, but I'm also sure I don't want to know how much that would cost.

http://foldingbikedestinations.blogspot.com/


Every developed or developing nation I've been to has cardboard recycling behind major stores. In Norway they had a gigantic one behind a Plantatia (Norwegian version of pottery barn). In Germany I got some behind an Aldi's. Even in the United States, the nation which recycles the least, you can find mountains of cardboard behind pottery barn, pier one, sears and so forth. I've never bought a cardboard box in my entire life.

http://usera.ImageCave.com/hvatum/cardboard_dumpster.jpg

Look for something like this. I personally have used the cardboard box method to great effect. Bring a roll of packing tape and scissors (check in) with you so you don't have to buy anything there. :thumb: