Tandem Cycling - Packing S&S Case

Does anyone have any recommendations on using the velcro frame covers versus buying foam padding and cutting out places for the tubes like the Santana cases? I have heard that foam is difficult to cut correctly. I assume that TSA will be able to repack the foam case correctly or is this too much of an assumption.

Should I remove the disc rotors from the wheels? Or, should I just stuff soft things (or foam) between the wheels?

Hi rmac.
I just went through the drill of taking my bike to Italy. Having done it (the padding) both ways, I would suggest using the nylon covered foam with velcro. Spend the time cutting each piece to exact fit until you have the entire bike covered. You should not be able to see any paint. If you really want to get anal about it, cover your seatposts, stoker stems, etc. Then, get a Sharpie felt tip permanent marking pen - silver - and mark the name on each piece of covering. Store the pieces, corresponding to the bike part, in each separate S&S case so you are not hunting for them when it comes time to repack. Definitely remove the disc rotors as they can be easily knocked out of true during shipping. Also, remove your quick releases and get axle end plugs so your axles won't damage your case. Make sure you use chain stay braces too.
I don't think TSA will give you much problems. However, for security, I suggest you use a TSA lock and lock each case latch. Put the key to your case locks onto the TSA padlock, so they can get into your cases.
Be sure to read my "airline excess baggage charges" thread so you won't get caught with the same problems I did. People that posted in the thread have a lot of great suggestions.
Enjoy your trip, wherever you go.
Cheers

Where can you buy the nylon covered velcro?

Where can you buy the nylon covered velcro?

Any S&S retailer / authorized builder (e.g., Calfee). You can find a listing at S&S Machine's website here (http://www.sandsmachine.com/retlist.htm).

Chichi, since you have a Calfee, you will need one roll of the 9" nylon covered velcro, in addition to the other widths, to cover your top tube, down tube and boom tubes.

Thanks VaultGuru for the advice. I'll get the velcro padding.

Calfee has some good prices on the padding and you don't have to buy full rolls -- just what is needed.

http://www.calfeedesign.com/coupler.htm

Put the key to your case locks onto the TSA padlock, so they can get into your cases.

If you give them the key, then what would be the point of using the case locks? The security would not increase by doing so, it would still just be the TSA lock is the only form of security; if you can open the TSA lock then you can open the case, regardless of whether you don't use the case locks or you use them and put the key on the TSA padlock. Maybe I'm missing something here?

One extra piece of security. I have "lost" locks when TSA "forgot" to put the lock back on securely. The case locks were locked however. I always carry an backup case lock key with me in the event this happens. No guarantees however.

Pipe insulation works well, cheap, easy to work with (all you need is a utility knife), and readily available. (Home Depot, Lowes etc.)

We have a couple of bikes in the standard S&S cases with the velcro/foam pads AND a Santana Case with the cutout foam. The cutout foam is far easier and quicker to pack and unpack however the case has to be much larger so it rarely flys for free (of course airlines are charging for all checked bags now anyway.....).

If you plan to travel a lot and your trips are short the cutout foam is the way to go.

... AND a Santana Case with the cutout foam.

What kind of foam are they using? Is it semi-rigid/closed-cell, soft-and-squishy/open cell or somewhere in between? I've seen the cases and foam, but it was a long, long time ago ('01 at ETR?) and I can't remember.

What kind of foam are they using? Is it semi-rigid/closed-cell, soft-and-squishy/open cell or somewhere in between? I've seen the cases and foam, but it was a long, long time ago ('01 at ETR?) and I can't remember.

Semi-rigid closed cell, it is pretty firm but I was able to trim it nicely with an exacto knife.

Make sure you allow plenty of time for packing and unpacking, it was a surprise to me how long it takes, not that any step is particularly time consuming but once you add them all up...., you can do it in just over an hour once you are handy, but it will take you at least two if you want to enjoy the job with a cup of coffee.

an additional consideration for ease in packing. After you have it packed to your satisfaction take digital pictures and slowly unpack it again taking pictures as you go. Print and them laminate them so you have a quick reference every time as I never seem to pack it the same way twice and sometimes it comes out better then others until I took the pictures. I just leave the laminated sheets in the cases. also put a laminated copy of your drivers license or passport inside in case your luggage gets lost and the tag gets ripped off. Every trip put a copy of your itinerary in also for the same reason. I like the TSA nets that S&S has to help with TSA inspections also

Does anyone have a source for the foam? I checked online but the only places I saw had pretty outrageous prices for the foam designed for this type of packing.

Mark W

We have about a medium/small Calfee. I was surprised that I have to take the fork off in order for the front part of the frame to fit in the S&S case. Even then, it fits fairly snug. Anything larger and it would have to be split in front of the pilot's seat tube rather than behind. Does this tight fit occur with other bikes (such as Santanas) that break apart behind the seat tube?

My wife and I took our Co-Motion Co-Pilot to Italy last year and used the velcro padding. The packing and unpacking worked like a charm We also brought along one of those oil-cloth table cloths (vinyl on one side and fabric on the other) We put the table cloth on the ground, vinyl side down and had a nice soft white surface to assemble the bike on.
Cheers!
Dave Kassner

We have about a medium/small Calfee. I was surprised that I have to take the fork off in order for the front part of the frame to fit in the S&S case. Even then, it fits fairly snug. Anything larger and it would have to be split in front of the pilot's seat tube rather than behind. Does this tight fit occur with other bikes (such as Santanas) that break apart behind the seat tube?

Yes, even after removing the fork.

Not so if you use Santana's large case (which we do not like because it makes transportation from airport to hotel very difficult).

Couple more questions about packing. Inflating the tires with a small pump is going to be a pain. I don't think CO2 cartridges are allowed on planes. Any suggestions on how to make this easier? Is packing a torque wrench or a large wrench for the cranks neccessary?

Couple more questions about packing. Inflating the tires with a small pump is going to be a pain. I don't think CO2 cartridges are allowed on planes. Any suggestions on how to make this easier? Is packing a torque wrench or a large wrench for the cranks neccessary?

Options for a portable pedal wrench have recently been discussed in the Bike Mechanics forum: Multi tool with pedal wrench, chain breaker (http://www.bikeforums.net/showthread.php?t=500206&highlight=wrench+pedal+multitool). For a pump, I agree that a small pump is not really the ideal thing, so I've just ordered one of these (http://www.chainreactioncycles.com/Models.aspx?ModelID=25647), a small-ish pump, but it has flip-out mini foot stand and a short hose. I'll let you know how well it works for us, but I've read good things about them.

+1 one on the mini foot pump this is the one we take:
http://www.dunhamssports.com/product/index.jsp?productId=2464715

We take a pedal wrench but no torque or crank wrenches.

Thanks, I'll try that pump and try to minimize the tools I take.

Topeak road morph http://www.mtbr.com/cat/accessories/pump/topeak/road-morph-pump-with-gauge/PRD_359296_136crx.aspx

not too big and WORKS GREAT:thumb: