jameswelle

Do bike boxes come in large enough sizes to fit large touring bikes (like a 61cm Rivendell Atlantis with racks and fenders)? We tried to pack up our bikes in some Specialized boxes tonight for our flight to New Zealand and were surprised to find that they didn't fit with the racks and fenders. We had to remove them and a couple of other things to get the bikes in the boxes. For the future, we'd like to know if we should search around for bike boxes that will accommodate our large bikes or if we are always going to have to disassemble. Thanks.

James and Sarah
jamesandsarah at erck dot org
We are documenting our trip at https://www.erck.org

Cyclist0094

Cannondale boxes seem to be a bit bigger, but on nearly all bike boxes the box ends an inch or so in front of the fork drop outs which means you have to remove the front fender and front rack. Be sure to fit a 100mm spacer between the fork drop outs so your fork doesn't get crushed by the luggage they will stack on top of it. I haven't flown a bike overseas in 20 years, but the airlines used to provide (sell) you their box which was pretty large.

vik 

I recently had to box up my LHT on the return flight to Canada from LAX. I ended up using two bike boxes. The first for my frame w/ rear rack attached & handle bars detached. The second for my wheels, seat/seatpost & front rack.

Happily my air line didn't charge me anything for the bike in two boxes even though they charged me $42 coming the other way when the bike was in one larger box - go figure.

If you have time it is definitely worth going to several LBS and seeing what boxes they have. All boxes are not made the same.

Rowan

The airline boxes (at least those in Australia) are way, way bigger than the boxes you might get from the LBS. My touring bike fits in with the rear rack attached, but not the front because the forks are always turned inwards anyway. I can imagine two racing bikes fitting in them. Having said that, the thickness/quality of the cardboard also can vary.

If your bike is a large frame from a shop or it was shipped at some stage, it must have come in a large box that fitted it. But, bike shops do tend to hand over whatever is at hand, and the box may have been for a small-frame MTB, not a medium or large-frame road bike. It's not only length, but also height you have to watch out for... and letting air out of your rear tyre can help just a little bit.

If you find a box that fits to your requirements, measure it, and use that as your guide in the future if you are collecting one from an LBS.

OBXBIKR

Get a cruiser bike box from your LBS. Big enough to pack with the rear wheel on my 60" Co-Motion.

FlowerBlossom

You just might have to take off fenders and the rear rack. I know it's a pain, but, you do want your bike to get there safely. It all depends on what your comfort level is.

When I traveled overseas this fall, I got the biggest box the LBS ever has. My bike is a 21", relatively smaller than yours (I haven't measured it c-c; it came as a '21inch', fits me fine, so I don't worry about the real frame measurements). Anyhoo...with the rear wheel on, front wheel off (and front forks facing rear, handlebars off/out), the rear rack stuck out above the top of the box approximately 1-2". The LBS wasn't surprised, and was great about talking me through some options. I chose what I was most comfortable with.

5 more

[QUOTE=FlowerBlossom]Anyhoo...with the rear wheel on, front wheel off (and front forks facing rear, handlebars off/out), the rear rack stuck out above the top of the box approximately 1-2". QUOTE]

You could loosen the bolts on the drop outs and remove the seat stay screws and swing the rack down. That way it acts like a "bumper". Cheaper(?) to replace a rack then a rear wheel.

Check out this site on the way they pack a bike https://members.shaw.ca/boxyourbike/

Vin

FlowerBlossom

[QUOTE=5 more]Wow, nice website!!! Thanks for the link. I like the idea of the liner for the box, the coroplast. Problem with that is, if you do a trip that is A->B, not round-trip, you've invested in a box that you can't use again. I wonder if double-lining with cardboard(another bike box?) would be enough. And, you might have to worry about weight issues with the double-box idea if you like to pack your box with clothes and other trip necessities. That coroplast looks like it might be a lot lighter than cardboard.

I have to argue that the difference with the bike on the website is that the bike doesn't have fenders or a rear rack, which was the issue with the OP. In the section "Packing the Bike", 2nd photo, looks to me the rear wheel is still in the dropouts.

I should have taken a photo of my "bump in the box"; it was truly negligible. But, on bigger frames, like the OP's bike, it would definitely be a bigger issue. No pun intended.

5 more

[QUOTE=FlowerBlossom]The link is off subject but I thought it would be of interest to others. As far as investing in and not using the box again it might be of use to others at end of their trip. I would keep the back wheel in the frame it all possible as it protects the crank rings, frame and wheel from damage.

ciadelle

I flew out of Portland, OR and United sold me a box for $15 which was HUGE. I took the pedals and handle bars off and wheeled my Kona Sutra on in.

Ken Brown

That tip about the front forks facing rear makes a significant difference. You have to take the fender off, but that is not difficult.
Get the box from a LBS that sells road/touring bikes. Mountain bikes are smaller. I got a Cannondale box and it was sufficient for my bike (which is quite large, 25+"?) with the rear rack & fender intact.

centexwoody 

So, Ken, is this how you've boxed your bike to ship over for your European tours? I've enjoyed your travelogues and have been to a number of those places but not on cycle tours. Last fall I was in Bonn for 5 weeks and this summer to Duesseldorf. In the fall I bought an aluminum cross bike at a Bonn LBS & rode it. But this summer I'm seriously considering taking my Surly LHT. You've had success keeping rear rack & fender intact and just removing / packing the front parts?

BTW, which is the 'best' airline you've flown with your bike boxed?

centexwoody

ken cummings

Any possibility you could just make your own custom box?

Ken Brown

Both my Europe trips were with Air Canada, but the actual plane could be one of their Star Alliance partners. Flying out of Toronto the bike will be loaded by AC even if it is a Lufthansa or Austrian Airlines plane, while returning it will be loaded by the European airline. I am always more confident when returning.

For my first trip I could not find a box large enough, so I fastened two boxes together. For my return from Vienna I got a box from a LBS and they told me about reversing the forks. Had I known that in advance my box from Toronto would have been good enough. However, as someone else asks, making one longer box out of two smaller boxes is possible. I used short bolts with large washers, plus lots of tape.

My second trip I stayed in the same hotel my first and last nights, near the airport. They stored my box for the return trip, but it had to be folded flat, which is easy to do. I had greater peace of mind than I had on my first trip, when I had to wonder whether I would find a box for my return trip. Turned out I had no problem in Vienna, and they were even a Cannondale dealer so they gave me a Cannondale box for my Cannondale bike.

avatarworf

If you are in Canada VIA Rail sell the biggest bike boxes you've ever seen. Perfect for tourers, just roll right in. Great fun to watch the expression on the check in agents at the airport too when they see your huge box