Bike in a bag
The travel case I use to transport my 2006 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.
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. A thick foam shell surrounds the bicycle and an additional outer layer of high-density polyethylene is added to the sides to add a degree of puncture resistance to the case My travel case can accommodate two bicycles.
Packing the bike for travel involves removing the wheels, pedals, seat post, 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 attached to the handlebars 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 cassette hub from the rear wheel but I do tape a piece of foam over it to add an additional layer of protection. The seat, seat post, pedals and axle skewers are wrapped in foam and placed in a nylon bag along with tools, chain oil, pump, etc.
Travel case mobility is provided by four casters bolted firmly to the base of the travel case. Though bulky, the case is easy to transport under human power. For the Amsterdam trip, total weight of the packed travel case equals 28.5 kg. My other piece of baggage weighed in at 50 kg.
I flew on Northwest Airlines out of Detroit. There was no additional charge for transporting my racing bike as it constituted one of my two checked bags.
BikePro USA travel case
Manufacturer: BikePro USA
2006 Trek Madone 5.5
Frame - OCLV 120 Carbon Aero
Fork - Bontrager Race X Lite, carbon
Stem - Bontrager Race Lite, 7 degree, 31.8mm
Handlebars - Bontrager Race Lite w/BzzzKill, 31.8mm
Brakes - Shimano Dura-Ace w/STI levers
Wheels - Bontrager Race Lite
Tires - Bontrager Race X Lite, folding, 700x23c
Front/Rear Derailleurs - Shimano Dura-Ace
Finish - candy apple red
Manufacturer: Trek USA