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Make you own bike case Bookmark

During my studies I travel with my bike, each time with a different airlines and bike cases. At that time, I didn’t think on make my own case. In this article, I described a carton box reinforced with a custom aluminum structure to improve the safety of the bike.

Custom bike case

Previous case

I used various cases during my traveling, from carton box, soft cased to hard cases. Below some pictures.

Cardboard box

Bike Cardboard Box - How To Fly With Your Mountain Bike

Soft case (Decathlon)

Image result for bike case decathlon

Hard case

Image result for bikecase

New approach

My last bike case (hard) was sold to a friend that bought a triathlon bike and need a hard case to protect his investment and new toy. After that moment, I was free of any bike case, which means I need to figure out a new way to travel with my bike safety soon.

The new approach consist in use a cardboard box (from a local bike store) and an aluminum structure based on angle, plates, screws and nuts. The design could be adapted for your need and material available with your local providers.

Cardboard with aluminum reinforced structure

Cardboard size

I used a box of 138cm x 19.5cm x 74cm from Giant.

Cardboard size

Adjustment due to material available

During the search and purchasing of the material, I didn’t find a long plate for the cross section. As shows the pictures, the long plate was reduced to the corners of the box. I prefer this solution than the original because improve strangeness and reduce weight.

Assembly and packaging

The holes for the screws were made during the assembly. The top structure use wing nuts for easy assembly/disassembly (not tool needed). A small fix was done in the cardboard as show the pictures (in the top) to avoid the wing nuts to fit.

A small fix was done in the cardboard as show the pictures (in the top) to avoid the wing nuts to fit

Structure assembledDuring the search and purchasing of the material, I didn’t find a long plate for the cross section.

During the search and purchasing of the material, I didn’t find a long plate for the cross section. All put together

All put togetherAt the end, cloth tape to protect the carboard and close it

Final package

Weight

The aluminum structure weight is 2.4Kg while the cardboard itself is 3.5Kg, for a total weight of 5.9Kg for this custom bike case.

Aluminum structure weightCardboard and aluminum structure weight

My final weight for checkin with the airlineEverything went well in the airport

Fee

Take in consideration (if is you first time traveling with bikes) that your airline will probably have a fee to transport your bike. During my traveling I paid from 50 to 150 USD to bring my bike. If you are traveling a lot and you are looking to reduce (or remove!) this fee, I suggest to try a soft case declaring it as anything different of a bike, as described by Ray here.

Drawings

You can download the drawing (2D and 3D) including an estimation of material used here.

Click to download drawings 

Testing

During a travel in Asia the bike case was in perfect conditions, except some scratches in the cardboard which were stop by the aluminum structure, hopefully!

Some scratches in the cardboard which were stop by the aluminum structure

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