Touring - TSA and your boxed bike?

This summer I will be flying to the UK to tour Wales. This is my first time taking my bike on a plane. I am pretty confident I can box it up and it will arrive undamaged. My concern is the TSA inspectors will open the box, pull out the bike and gear, and then not repack it securely. Leaving the bike vulnerable to damage by the luggage handlers.

Has anyone had this problem or have any advice on how to avoid such a situation?

Thanks in advance. Ken

You should assume that TSA personal will open the box, take things out, and then repack it.

If you have inserted packing material around the forks and the rear dropouts, you should attach it to the bike somehow (tape or zipties) so that it will stay in place when repacked.

I'm sure the people at TSA are experts at getting something to fit inside a suitcase!

Pack it so that it can be inspected and repacked by someone who doesn't care how hard he has to push down on the lid to make the box close.

If you pack it so it explodes when opened, it's just not going to be put back right.

Pack a starting pistol in with the bike. You MUST declare this when you check your bag at the counter. A TSA employee will ask you to open the bag, he will inspect it, you can then lock it with a non-TSA approved lock. The bag is very closely monitored from departure to arrival (seems TSA is touchy about missing firearms) and will not be opened by anyone else after the initial inspection.

The downside is you have a firearm that you have to deal with. You could leave it at the bottom of your pannier, or you could toss it, or you could swing by a local college and donate it to the track or swim team.

http://blog.jonudell.net/2007/05/09/amazing-lifehack-pack-a-starter-pistol-to-deter-luggage-theft/

The suggestion I've heard is to either: 1) make the boxed bike extremely easy to pack, or 2) include printed packing instructions inside the bike box. If you include instructions, numbered steps with pictures seems to work better than large amounts of text.

I have flown with a bike several times. Each time TSA simply looked inside the box without removing the bike. I was permitted to be there during the inspection. After the inspection the TSA agent tapped the box back up, under my direction. They have always been very helpful and cooperative.


Italy was the strangest of all. They took a quick peak inside the box,, they then put it back in my possession and I was instructed to take it to the loading area (not accompanied by anyone).

I've gotten best results by not boxing the bike at all, just turning the handlebars sideways, lowering the saddle and taking off the pedals and lights. Baggage handlers see a bike and lay it on top of everything, and TSA doesn't have to open it. A big clear plastic bag is the most I've ever used.

I am not likely to ship my bike by air anytime soon. However, I have taken Amtrak several times from Portland Oregon and return. No hassle about the bike ever!

I have taken my bike from Denver to Emeryville by Amtrack. They provide a box for $5 and a baggage handling fee of $10. Never any problems. I am going to Italy this summer and purchased a Ritchey Breakaway with Case. Should be easy to pack so TSA can inspect and repack. I am going to remove the tires and tubes and fold them with rubber bands so they can easily inspect everything without taking too much out of the bag. I may or may not be charged for oversized baggage. I will try and pass for AL legal.
If you plan on travelling often with a bike then get couplers and a case.
Build a bike box like a gift box and use straps to hold the box together. That way they will lay the box flat, remove the straps, and open the box so that the entire bike is exposed. That way they won't have to remove and repack the bike in the box with much effort. Just an Idea.

It's been my experience that they do not take the bike out of the box. But a couple of times they have had trouble re-attaching the exterior straps. I watched them struggle in Portland and offerd to help. The TSA agent told me that I was not allowed into the area and could not touch the box since I had checked it. (Stupid with them standing there.) Later, the same thing happened in Philly. The TSA agent having trouble actually asked me into the searching area to re-attach the straps.

I have also flown with a bike in a large, clear plastic bag. I (and the bike) took three flights to get back to the U.S. from Spain. Only concern was a minor tweek of the rear wheel. I think there is merit to this suggestion because I can see them being less likely to treat an un-boxed bike as "luggage" That's precisely how America West treated my boxed bike in 2002. One handler picked it off the luggage cart and tossed it forward about 5 feet from waist high onto the tarmac.

I have boxed a bike often, and always leave printed instructions with the box, including politely asking the TSA people to be careful. There's never been a problem. I'm sure those who swear by using no box have had good experiences, but I can't imagine shipping a bicycle worth thousands of dollars that way personally. Of course, if you have a hybrid or mountain bike, it's much more durable and able to hold up under rough handling.

I boxed mine to Ireland last summer and while they did open and check it, they returned it to proper packed condition. I bagged on the way back, which was a bit more of a pain IMO as it was a bit more of a pita to move around the airport. However in both routes I had no damage. And with aer lingus there are no fees for the bike.

The following may or may not apply to a boxed bike. Having said that, I have flown many times with a Bike Friday which folds and partially disassembles and then packs into a regular hard plastic suitcase. At one airport that I have used several times, the TSA operation is visible to passengers. Each and every time, they have opened the bicycle suitcase, swabbed it (presumably for explosive residues), run the swab through a testing machine. Then when the swab passes (it always does), they have simply closed the suitcase and sent it on its way. I have watched this same procedure several times and it has never varied.

Personally, I wouldn't be the least bit concerned about TSA handling a regular bike in a box. Enjoy your trip to Wales.

I've flown from LAX Bradley (International) many times with my bike. They just put it in the ex-ray machine and thats it. Never have opened the box.

I am now back from my tour of Wales and had no problems with shipping the bike.

I used the top load method (that's what I call it) to pack it. Obtained a bike box from my LBS and (after some disassembling) lowered the bike down into the box. To secure the top flaps down I cut small slits (3) into the each side of the box about 12 inchs down from the top. I then took the straps (with snap buckles on the ends) and pushed them through the slits and brought the ends up over the top, fastening them. This allowed an inspector to open the top of the box and easily look into it.

On arriving in London there was no damage to the box and I was able to open the box and quickly look inside. Everything was fine.

For the return flight I was able to get a box from a LBS in Cardiff and used the same method. Again there was no problems when I arrived in Denver.

All your imput was very helpful. Thanks, Ken

Curious if you guys put your panniers in the same box, or if you check them separately.

Curious if you guys put your panniers in the same box, or if you check them separately.
We usually get one of those 18" cube boxes from a Public Storage or whatever they call it place and put the panniers and a few other things in there. Seems some carriers have a 50 pound weight limit per peice of checked baggage, so putting panniers in the bike box might put you over and no sense giving people a chance to look for overweight charges.

We usually get one of those 18" cube boxes from a Public Storage or whatever they call it place and put the panniers and a few other things in there. Seems some carriers have a 50 pound weight limit per peice of checked baggage, so putting panniers in the bike box might put you over and no sense giving people a chance to look for overweight charges.Good idea. Also, I assumed that the airlines charged a big fee for bikes. If so, do they still stick to a 50lb limit?

This summer I will be flying to the UK to tour Wales. This is my first time taking my bike on a plane. I am pretty confident I can box it up and it will arrive undamaged. My concern is the TSA inspectors will open the box, pull out the bike and gear, and then not repack it securely. Leaving the bike vulnerable to damage by the luggage handlers.


Why would they do that when the X-ray machine your bicycle will have to go through is extremely detailed and can identify exactly what you've got in the box?

-- Arrive at the airport early.
-- Check your luggage in.
-- They will send you to the X-ray machine and if you've arrived early enough and they aren't too busy yet, they will let you look at the monitor. If they have any questions, they will ask you.
-- Take the bicycle box wherever they tell you to take it after it has been cleared by X-ray.

Curious if you guys put your panniers in the same box, or if you check them separately.

It depends.

But one thing you've got to be careful of is weight. Airlines are cracking down on the weight limits of all luggage so you don't want to pack your panniers in your bicycle box if they will make your bicycle overweight.

It depends.

But one thing you've got to be careful of is weight. Airlines are cracking down on the weight limits of all luggage so you don't want to pack your panniers in your bicycle box if they will make your bicycle overweight.
I did some googling and see that each airline has its own prices. I see they're still flying golf clubs for free, but not bikes. Grr..

Not sure, however, what the price difference is between checking an additional bag or paying an overweight fee for one checked bag.

I did some googling and see that each airline has its own prices. I see they're still flying golf clubs for free, but not bikes. Grr..

Not sure, however, what the price difference is between checking an additional bag or paying an overweight fee for one checked bag.

Why would you have to check and additional bag?

When I tour, I pack my stuff in two "bags":

1) Bicycle box with bicycle and empty panniers
2) Duffel bag with the stuff that will go into the panniers.

OR

1) Bicycle box with bicycle
2) 2 full panniers, bound together with a cinch strap so that they are 1 bag.

And I take my Carradice and handlebar bag as carry-on.


This site gives some information regarding travelling with your bicycle:
http://www.ibike.org/encouragement/travel/bagregs.htm

Curious if you guys put your panniers in the same box, or if you check them separately.
I never put stuff other than the bike and racks in the bike box. I figure that the TSA is less likely to actually remove the bike from the box that way and are more likely to just open the top and look in. And yes they do often inspect bike boxes.

The following ways of packing panniers and gear have worked for us:

We bought thrift shop suitcases ($6-7 each) and discarded them at the destination.
We used cardboard boxes, but have had to sign a waiver saying the airline was not responsible for damage (only loss) or else they said they would refuse the boxes.
We packed the panniers and their contents in a canvas duffel bag.


On Amtrak I have just strapped the panniers together in two bundles and taken them as carry on. I would be nervous about that method for checked baggage on a plane though.

Good idea. Also, I assumed that the airlines charged a big fee for bikes. If so, do they still stick to a 50lb limit?

Yes on the 50 pound limit or else the bike will either be refused or hit with another large fee. BTW: we found SouthWest to be quite bike friendly. They take the normal two checked bags for free and only charge an additional $50 for the bike (which counts as one of the two checked bags). Since most of the other airlines charge for any checked bag and hit you for a much larger fee for the bike that is a good deal. Note that SW flights often do not show up on expedia and similar sites, so if necessary go directly to the SouthWest site to book.

We travel with our S&S tandem internationally at least once a year. It's in two boxes. We almost always have one of the TSA's "we inspected it" cards inside at least one case. Never any troubles with things being repacked.

Several years ago we were flying home to Philadelphia from the Munich airport. We were taking apart our tandem outside the departures terminal and packing it up. An airport worker on a smoke break was watching us intently, and asked a few questions. When we went inside, it turns out he was one of the security checkers and basically waved us through,telling us he would make sure everything was ok with the bike. Now that's good luck!

My solution to this is a soft sided bike bag and to use my gear as packing material. I bought a Ground Effect Tardis bag (http://www.groundeffect.co.nz/product-detail-TAR-BAG.htm) for a recent trip from the USA to the UK and it worked really well. The bag weighs 2lbs and can be carried relatively easily, put in left luggage, mailed ahead of left at a hotel. The big advantage is that the bag can be easily carried and put in the trunk of a taxi so there's no issues with getting it to the airport like there are with bike boxes.

http://wheelsofchance.org/england-2009/

Below are some boxed and unboxed pictures from my recent tour in Ireland. My advice is ZIP TIES...ZIP TIES...ZIP TIES and PIPE INSULATION. I had my bike packaged so when
removed from the box it lifted out as one unit. TSA inspected it and put it back perfectly. I used a cardboard bike box from my local bike shop. I covered
the box with a cheap tarp from Walmart. With a cheap skateboard and some laminate flooring, I made it roll. It worked great!

Bike box - Free
Tarp - $5.00
Skateboard - $15.00
Flooring board - Free

170144170145170146170147170148170149170156http://www.bikeforums.net/images/misc/pencil.png

Below are some boxed and unboxed pictures from my recent tour in Ireland. My advice is ZIP TIES...ZIP TIES...ZIP TIES. I had my bike packaged so when
removed from the box it lifted out as one unit. TSA inspected it and put it back perfectly. I used a cardboard bike box from my local bike shop. I covered
the box with a cheap tarp from Walmart. With a cheap skateboard and some laminate flooring, I made it roll. It worked great!

Bike box - Free
Tarp - $5.00
Skateboard - $15.00
Flooring board - Free



Neat packing job. The thing I like about the Tardis solution is that the TSA can simply unzip the bag and everything is in front of them. By packing clothes and other gear inside the bag you get plenty of padding and don't have to deal with multiple bags at the airport. It's also easy to sling the Tardis over the shoulder and there's no need to search for a box on the return journey. I usually pack my bike and gear the night before I leave and just take a bus/ subway or taxi to the airport. I would never try to take a boxed up bike on the subway, but it was easy to get the Tardis onto the London Underground.

Why would you have to check and additional bag?

When I tour, I pack my stuff in two "bags":

1) Bicycle box with bicycle and empty panniers
2) Duffel bag with the stuff that will go into the panniers.

OR

1) Bicycle box with bicycle
2) 2 full panniers, bound together with a cinch strap so that they are 1 bag.

And I take my Carradice and handlebar bag as carry-on.


This site gives some information regarding travelling with your bicycle:
http://www.ibike.org/encouragement/travel/bagregs.htm
By additional bag, I mean in addition to the bike box. Some airlines charge for all bags. My upcoming tour will be the "light" variety and I hope to be able to stuff it all in the box or carry some of it on. I think my gear will be less than 15 lbs. Only concern is carrying on anything that might get the boot from security, but not sure if anything would.

Only concern is carrying on anything that might get the boot from security, but not sure if anything would.

I carry my clothing in my carry-on bag(s). If they were to dig through my Carradice or handlebar bag, they'd find things like ... 2 pair of cycling shorts, a pair of basketball shorts, 2 wicking T-shirts, a long-sleeved merino wool top, socks, underwear ...

Once I arrive at my destination, then I rearrange the contents of my bags so that everything is in the right spot for touring.

I carry my clothing in my carry-on bag(s). If they were to dig through my Carradice or handlebar bag, they'd find things like ... 2 pair of cycling shorts, a pair of basketball shorts, 2 wicking T-shirts, a long-sleeved merino wool top, socks, underwear ...

Once I arrive at my destination, then I rearrange the contents of my bags so that everything is in the right spot for touring.

Because my gear is relatively light I can easily fit it in the Tardis along with my bike. The whole thing weighs 40lbs and can be carried over the shoulder so it's very convenient. I carry my handlebar bag onto the plane as it has all the things I need off the bike.


http://wheelsofchance.files.wordpress.com/2009/07/waiting4.jpg

You should assume that TSA personal will open the box, take things out, and then repack it.

If you have inserted packing material around the forks and the rear dropouts, you should attach it to the bike somehow (tape or zipties) so that it will stay in place when repacked.

I'm sure the people at TSA are experts at getting something to fit inside a suitcase!

It seems they are also getting better at treating personal belongings with respect.

A while back I came back to Canada via LAX from bicycling outback Australia and opened a bike box when back home. The packed dirty bike parts were mixed with (originally clean) clothes and books when I opened the box upon arrival in Canada. Two boxes of cookies were crushed and wrung like dirty sox being washed. Then there was a stack of TSA leaflets stating the box was inspected. My wife looked at the contents and the mess and stated that their "inspection" had nothing to do with "security".

I have not flown through the USA again - until on the 19th when a bag was opened at ORD on the way to LHR. No problem with the TSA handling my stuff during that inspection.

in most regional american airports, a traveller will not get a chance to go anywhere near the TSA baggage screening area.

my adaption to travelling with a bike was to purchase a SNS coupled TravelersCheck. no oversized charges.

Easy in and out of the box with the security netting. a tip for anyone with a SNS bike and a hard case - leaving the tire off the top wheel makes it infinitely easier to pull out and repack the bike and close the top without a lot of gladhandling.... like melted butter. i can even fit a folding Racktime rear rack in the box with the bike!

My Trek 520 has S & S Couplings. This summer I took it to Europe packing it in a softside case that I purchased from S & S. I ziptied the bike and then packed the case with addtitional luggage - panniers, bike shoes, etc. I also printed out instructions and photos on how to pack the bike and case and placed with the bike. Sad to say TSA did not take care to inspect and repack the bike on the return trip. Both wheels were tweaked and the frame scratched. The next time I try this I think I will not be so diligent about filling the case so that it will be easier for TSA repack.

in most regional american airports, a traveller will not get a chance to go anywhere near the TSA baggage screening area.

my adaption to travelling with a bike was to purchase a SNS coupled TravelersCheck. no oversized charges.

Easy in and out of the box with the security netting. a tip for anyone with a SNS bike and a hard case - leaving the tire off the top wheel makes it infinitely easier to pull out and repack the bike and close the top without a lot of gladhandling.... like melted butter. i can even fit a folding Racktime rear rack in the box with the bike!

No over sized charges for the Tardis either and it's a cheaper way to go than S&S and a hard case. Of course the level of protection isn't as high

i find it hard to believe that bag does not exceed the airlines standard maximum dimensions of 26" by 26" by 10", nun, and that you haven't run into an overzealous counter attendant with a tape measure.

you must be lucky.

Are you sure it only weighs 2 pounds? The ground effect web site lists it a 1.45 kg (about 3.2 pounds). I ask because I figure that the difference would likely be the make or break difference for carrying it along on tour for some riders.

Do you manage to check it without oversize baggage charges? It does look like it would be well over 62" (L+H+W).

Edit: I see you already said you don't have to pay oversize charges. Is it actually under the 62" limit (it sure doesn't look like that is possible) or have you just been able to slide on that?

I have the Tardis but the one time I took a bike in it, I chickened out and packed it into a cardboard box.

I am concerned about what happens to the wheels if the airline lays it on the side and then chucks another bag on top of it. Just find it hard to believe that a bag with no protection or padding can actually be safe for the bike.

V.

Pack a starting pistol in with the bike. You MUST declare this when you check your bag at the counter. A TSA employee will ask you to open the bag, he will inspect it, you can then lock it with a non-TSA approved lock. The bag is very closely monitored from departure to arrival (seems TSA is touchy about missing firearms) and will not be opened by anyone else after the initial inspection.

The downside is you have a firearm that you have to deal with. You could leave it at the bottom of your pannier, or you could toss it, or you could swing by a local college and donate it to the track or swim team.

http://blog.jonudell.net/2007/05/09/amazing-lifehack-pack-a-starter-pistol-to-deter-luggage-theft/

I don't think any kind of pistol is a good idea for a trip to the UK. The suggestion works well in most places in the US, but gun laws in the UK would suggest it could be a problem.

I have the Tardis but the one time I took a bike in it, I chickened out and packed it into a cardboard box.

I am concerned about what happens to the wheels if the airline lays it on the side and then chucks another bag on top of it. Just find it hard to believe that a bag with no protection or padding can actually be safe for the bike.

V.

I've only flown on BA and Virgin and the Tardis was taken as regular baggage. The Tardis is 45"x27" and I use a strap to pull it tight width wise so it was under (or so close that they didn't measure) the 35"x29"x16" airline dimensions and less than the weight limit of 23kg. There was no extra charge. One time I was asked to carry the bag to the end of the check in rather than having them put it on the conveyor. The great thing about the Tardis is that it doesn't use up much of the weight allowance like hard sided cases can. The 2lbs I quoted was an estimate, but even 3lbs is pretty good IMHO. I wouldn't plan on carrying it far on the bike, but it's definitely possible to do that so you can ride to somewhere you can leave it, or post it. I solves the issue of finding and disposing of boxes and being stuck with nowhere to stash a hard sided case. It really does fold down to the size of a phone book so it's easy to stash in a locker and cheap to post.

Wheels are strong things and they go on the outside of the bag. I remove the skewers and replace them with those plastic discs. I use clothes and gear as padding and it has worked very well so far. The first time I used it I added cardboard as extra padding, but since then I've shipped it without the cardboard and it's worked fine.

I've only flown on BA and Virgin and the Tardis was taken as regular baggage. The Tardis is 45"x27" and I use a strap to pull it tight width wise so it was under (or so close that they didn't measure) the 35"x29"x16" airline dimensions and less than the weight limit of 23kg. There was no extra charge. One time I was asked to carry the bag to the end of the check in rather than having them put it on the conveyor. The great thing about the Tardis is that it doesn't use up much of the weight allowance like hard sided cases can. The 2lbs I quoted was an estimate, but even 3lbs is pretty good IMHO. I wouldn't plan on carrying it far on the bike, but it's definitely possible to do that so you can ride to somewhere you can leave it, or post it. I solves the issue of finding and disposing of boxes and being stuck with nowhere to stash a hard sided case. It really does fold down to the size of a phone book so it's easy to stash in a locker and cheap to post.

Wheels are strong things and they go on the outside of the bag. I remove the skewers and replace them with those plastic discs. I use clothes and gear as padding and it has worked very well so far. The first time I used it I added cardboard as extra padding, but since then I've shipped it without the cardboard and it's worked fine.
I would think that on most US airlines at anything much over 62" (l+h+w) you would get socked with an oversize bag charge at the very least and you are well over that. Frontier or Southwest would take it for normal $50 bike charge so it would work well there. Delta would almost certainly hit you with a $200 charge.

I have been shy about damage with soft cases so I have not tried one. Still, the possibility intrigues me. I am guessing that baggage handlers might possibly be less likely to stack stuff on top of a bike that is in a soft case than one in a box so maybe the risk of damage really isn't any worse.

I am unwilling to deal with shipping an empty hard case at either end of the tour, but a soft case than packs small could be mailed home or to the end point of the tour much more cheaply and easily than a hard case.

Those of you who have used soft cases on domestic US flights... Please chime in with your experiences. I'd really like to be convinced that this is safe enough and makes sense for me.

I would think that on most US airlines at anything much over 62" (l+h+w) you would get socked with an oversize bag charge at the very least and you are well over that. Frontier or Southwest would take it for normal $50 bike charge so it would work well there. Delta would almost certainly hit you with a $200 charge.

I have been shy about damage with soft cases so I have not tried one. Still, the possibility intrigues me. I am guessing that baggage handlers might possibly be less likely to stack stuff on top of a bike that is in a soft case than one in a box so maybe the risk of damage really isn't any worse.

I am unwilling to deal with shipping an empty hard case at either end of the tour, but a soft case than packs small could be mailed home or to the end point of the tour much more cheaply and easily than a hard case.

Those of you who have used soft cases on domestic US flights... Please chime in with your experiences. I'd really like to be convinced that this is safe enough and makes sense for me.

I've never flown domestically (inside USA) with my bike, so it may well attract fees there. However, the Tardis also opens up the possibility of using the train and bus as it's easy to carry around. It's bigger than an S&S style case, but a lot smaller than a bike box and can fit easily through doors and in any luggage rack/space.

I would zip-tie separate parts together. That way if they take things out, they can't screw it up. And yeah, as raybo said, try to tape some of the packing material to the pieces.

I've never flown domestically (inside USA) with my bike, so it may well attract fees there. However, the Tardis also opens up the possibility of using the train and bus as it's easy to carry around. It's bigger than an S&S style case, but a lot smaller than a bike box and can fit easily through doors and in any luggage rack/space.
Thanks for the follow up. It sounds like this method works very well for you. I have to wonder if it would work as well in the US.

My concerns are... I would be pretty hard pressed to keep total load below 50 pounds and am pretty sure that it would be treated as oversize baggage on US domestic flights even if I did. I also wonder about damage to the bike with a soft case. Still the notion of packing one big bag and heading off to the airport sounds great, even if it means I have to mail the bag ahead or home when I start my tour.

I am not too concerned about the train or bus since I find it pretty easy to just use an Amtrak box when riding the train and I try to avoid the bus.

I have fairly often read about folks either using soft cases or bagging their bikes in plastic, but I don't think any of them were in the US. Have any of you here successfully (or unsuccessfully) traveled that way on US domestic flights?

having watched baggage handlers and the seeming widespread disdain they possess for people's luggage,

there is no way i would travel domestic airlines with a bike in a soft case. expecting the handlers to treat a bag more gently because somehow they would know it has a bike in it is a hilarious assumption.