I just flew from Vancouver to Montreal with a pair of precious road bikes (one carbon, one alu-carbon). Air Canada charges $50 CDN per bike each way. This was my first experience but for what it's worth here's my report:
I bought a pair of soft bike bags (the second item on this page http://www.cdisports.com/carrying_cases.htm) and packed the bikes like this:
- Took off both wheels and replaced them by shipping spacers/braces (available for free from your bike shop)
- Took off skewers from wheels
- Took some air off wheels (but not completely - it's supposed to be pointless but some airline employees still think it's important so whatever)
- Took off pedals
- Loosened handlebars and turned them to the side and down
- Unscrewed derailleur from its holder (to prevent it from bending/breaking) and just let it hang loose, as per my mechanics' advice
- Padded the frame with styrofoam (a friend suggested pool noodles but we ended up taking pieces from an old camping mat) - that's extra peace of mind.
- ... that's it.
It took a bit of time because it was the first time but rebuilding the bike was pretty fast. (Just have to remember to screw the handlebars side screws first and the top one last next time.) Packing them when we go back home will be rather quick.
I chose the soft bike bags over hard cases because the hard cases are 1) bulkier and 2) tough to lug around if there are no elevator and 3) they take a whole lot of room at destination. The soft cases are 1) bulky, but we can squeeze them to fit two of them and two big suitcases in our Civic; 2) have a shoulder strap (but the model we have very badly needs more handles sewed to it) and 3) takes relatively little space when rolled up so we can leave them in a wardrobe. Another big plus of the soft case is that it can't be put UNDER a pile of other suitcases by airline employees. It goes in the "bulk" compartment of the plane's cargo.
The bikes arrived unharmed to Montreal.
However, note that two airport employees I've talked to recently, who also cycle, told me that the best mean of transportation for your bike is a clear plastic bag (taking the pedals off and turning the handlebars to the side). That way, airline employees can't do anything else with it than let it free stand. The thought of having his carbon bike fly in a plastic bag freaked out my boyfriend so I talked him into the soft case instead.
From other people's experiences, I would stay as far away as possible from cardboard boxes for flying airplanes.
Do not hesitate to ask if you have anymore questions...
EDITED TO ADD: We also tossed a lot of cycling clothes and other stuff in the bag. It gave it some shape (and gave us more space). We got chain protectors from the bike bag company so the clothes were unharmed / unstained by the chainring.



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