Here's a few tips and photos of one I did a few years ago and use a similar system still now...
Some excellent tips and ideas there, Fred; thanks for sharing.
Having flown to Amsterdam and back and suffered damage caused by careless TSA inspection on return stateside, I think I'll go a different route next time and ship the bike separately. I've had terrifically good luck so far using BikeFlights (
http://www.bikeflights.com/ ) and found them to be not only reasonable in cost but extremely reliable. Very easy to deal with and superb followup.
Basically, BikeFlights allows one to send their bike anywhere in the world via FedEx at commercial-account rates -- and with insurance to match. There is full tracking so you can follow the package progress, and they'll deliver pretty much anywhere you have an address, including hotels and motels and such. The are timely, and this makes it possible to ship bikes reliably to racing venues as well. I simply used a bike box from my local shop. By the way, if you're looking for boxes try for a Trek Madone box. They come with v-shaped foam frame tube standoffs and BB supports and quick-release nylon webbing straps to secure the lot. There's room for wheels next to the frame, but mudguards and racks will need to be removed for all to fit.
Taking a bike with you on a flight originating in America is increasingly expensive and adds considerably to the cost of a vacation. Too, when damage occurs -- as it did for me -- there is often little recourse. Because my damage was caused by the TSA and not an airline, no compensation was possible (a little inspection note tucked in the box stated this, and later calls confirmed it). I'd taken care to even fasten a photograph of the packed bike to the inside flap of the box, thinking it would make repacking easier in the even of inspection, but no such luck. The pedals were stove through the wheels, requiring me to build up a new pair on my return, the Brooks saddle was badly damaged, the handlebar tape was ruined and much of the paint was scratched. If all this has happened on the outward leg, the bike would have been unusable for my scheduled tour of Europe as the wheels could not have rolled a turn.
In contrast, my BikeFlights shipments have come through consistently uscathed and there is recourse available in the event of damage thanks to insurance.
Might be worth a look.
Best,
Dan.
