You’ve completed your point-to-point adventure, only to discover that every bike box in town is too small for your flight home. So what’s the plan now?
I’ve been in this situation more times than I can count, especially when I was travelling with a tandem that fit into exactly zero standard bike boxes.
With my current XL touring bike, I simply ask a shop for the biggest box they have, usually one meant for a medium or large 29″ mountain bike. Tracking down a suitably large box can take a bit of hunting, but it almost always works out in the end. Occasionally, I just need to fully deflate the rear tyre to squeeze everything in.
If you still can’t find a box that fits, here’s what I’d do next.
Extend The Length of a Bike Box
I’ll take (or buy) two bike boxes from a shop and cut the end off the one I’m using. Sometimes you’ll pay a small fee, but most shops will give them away for free.
From the second box, I cut a slightly longer section and will tape it onto the end of the first box. I always leave plenty of overlap so the join stays strong and the box keeps its shape.
When packing, I place the rear triangle toward the extended end so the fork can’t punch through the cardboard. This is exactly how I used to fly with my tandem about 12 years ago, and it worked flawlessly every time.
Make Your Own Bike Box
In truly desperate situations, you can build a surprisingly sturdy DIY bike box. I’ve had to do this when flying out of very small regional airports, or when certain bus companies refuse to take a bike unless it’s boxed.
Start by visiting a supermarket or store and gathering as many cardboard boxes as you can – larger ones are better. You’ll also need plenty of tape and around 30 metres of plastic wrap (cling wrap / cling film / saran wrap) per bike. Break the boxes down into flat panels, then tape those panels together into a sheet roughly matching the size of a regular bike box.
Lay the bike on this large sheet and wrap the cardboard around it, adding extra pieces on the bottom and across the top. At this stage, it will resemble a bike box, but it won’t be very rigid yet.
Now take the plastic wrap and circle the entire box over and over, pulling it tight each time. Wrap it lengthways and crossways to add strength from multiple directions.
Eventually, it becomes surprisingly tough. I’ve never had a bike damaged using this method, though these makeshift boxes typically only survive one or two legs of travel.