The travel case below is built around a steel frame I use to transport my Trek Madone 5.5 to Africa, Europe and North America is built around a steel frame that permits the bike frame and fork to be attached to the case in a manner similar to stationary trainers or car bike racks. A thick foam shell surrounds the bicycle with an additional outer layer of high-density polyethylene protect the sides of the case with a degree of puncture resistance.
Packing the bike for travel involves removing the wheels, pedals, seatpost and seat, handlebars and stem. I use pieces of foam secured by electrical tape to protect the frame and finish. The crankset, brakes, cabling and rear derailleur are not removed from the bike and the brake and drive train cabling permit the detached handlebars and stem to be hung next to the front fork. The wheels minus their skewers are placed in nylon wheel bags and are stored on either side of frame. I do not remove the hub. Seat, seatpost, pedals, skewers are wrapped in foam and placed in a nylon bag along with tools, chain oil, etc.
The bicycle frame's bottom bracket sits on an adjustable flex plate assembly and is secured with a T-Bolt between the rear stays. The front fork is secured to the fork mount with a quick release skewer. The rear derailleur is protected by a curved steel guard plate.
My travel case can accomodate two bicycles.
Total weight of both bike (carbon fiber frame) and travel case equals 28.5 kg.
Manufacturer: BikePro USA
Manufacturer: Trek USA