I have a Dahon Airporter flight case but it’s over the maximum suitcase dimensions for Iberia Airlines.

I thought I would see if I could fit my Tern into a standard (albeit large) suitcase.

This was the procedure:

Remove rear rack
Remove both mudguards (they’re not coming to Madrid)
Remove frame magnet clamp

Then:

Chain off
Rear derailleur off and zip tie to frame
Wheelset off, QRs remove and bagged up
Pedals off
Crankset off
Seperate handlebar and tower


That was about it!

I also packed the tools required for assembly and disassembly in Madrid

Quick Link pliers
Square taper crank extractor
4/5/6mm allen keys
Zip ties

Anyway, photos to follow. Disassembly was about 20 minutes and should be faster next time.

Pics or nunca sucedió.

Do you unscrew the rear derailleur? I was told to undo it and tape it to the frame to avoid bending the hanger

Tell us about your cycling plans in España.

OP: This was what I am expecting, to fly with my similar bifold Dahon Speed. My rear rack is a tall one, I figured to detach and nest around a wheel. My only question is if it will still all fit then under 62", or will I need to break up into 2 separate checked bags. Notably, I have a tall fixed stem, cannot telescope short, and the handlebar clamp does not open like later clamshell style, so would be ridiculous effort and at least an hour on each end to take everything off the handebar to slide it out of the stem. I love the height and rigidity of that stem, but perhaps I can find an aftermarket fixed stem in that height with a clamshell opening clamp. Although I still could not transport the handlebars in a different parcel without disconnecting all the cables. Better if I can put all into one.

Did you need to separate the handlebars from the upper stem? I do notice you have separated the stem bottom from the above, but can't see the handlebars. Thanks.

yes and yes.

I have 5 1/2 days in Madrid. I need to get around the city; I don’t think I will venture further afield.

Lose the rack for your trip.

The lower half of the handlebar tower is still attached to the frame/headset. The upper half is detached. The handlebar and extender are also unscrewed.

Let me know if you have further questions.

Thanks. If I traveled with my current bike, it would be with rack and panniers for self-contained touring. If I didn't need that, I'd get a Brompton clone for much easier transport everywhere. Given the combination of cheap lodging and restaurant food in many southeast Asia countries that sell clones, I'd consider flying there sans bike, buy a clone, credit-card tour, fly home with bike, save the $300 shipping to USA.