nisqualee

The Ritchey Break-Away bike case size exceeds airline baggage limits.

For Delta airlines this is 62" (H+W+L). The Ritchey travel case is 68".

Delta charges $200 for oversize baggage.

Has anyone found a way to pack one into a box that is 62" or less?

Thank you for your help.

fietsbob

Rather than wait for another with the same bike, to tell you ..

Make up something out of corrugated cardboard that is compliant and try it your self ..

or Find another carrier than Delta.. In-country tours , ship the bike Ahead on UPS.

The LBS , here, deals with Bike tourist's own bikes all summer. only a small fee ($10) to take it in and store it

if you write "Do Not Assemble", on the carton and DIY with your and borrowed tools when you arrive.

Ozonation

Not a bad suggestion. You could also try corrugated plastic and see if you could fabricate something.

62" total linear dimensions is standard on just about every North American based airline. If you're flying to Europe, check ahead: many airlines there have check in bag dimensions less than 62".

The other thing to be very careful about is weight. I have the B&W case for my Brompton, but once you pack in a few extra items that you can't bring on board (multi-tool, lubricant, CO2 catridge) or don't want to wrestle with on board (helmet, etc.), you'll find you'll probably be right at the 50 lb limit threshold.

ZenNMotion

The Ritchey case is 26x26x10 inches measured along the edges, so it makes the 62 inch limit if it's not overstuffed with other things. I place the bag on the scale with the bubble facing away from the agent. I've made more that 40 flights with mine, most international but some domestic as well including Delta and only had an agent question the bag a few times, and I've never paid extra, knock on wood. Trying to build your own case seems like a frustrating waste of time. Curbside check iin is easier if you can (and tip generously- those guys make very little), carry a print out of the airline baggage regs, always be polite but firm if there is any issue raised.