The first step to acquire a bicycle box, which can usually be done free of charge by going to a bike shop and asking for one. These are the boxes that new bikes come in when the shops first buy them.
Next, you will need to partially diassemble your bicycle to fit into the box. Take off your front wheel, pedals, saddle, loosen your handlebars so they turn sideways (or hang free), and unscrew your rear derailer where it attaches to the frame, allowing it to dangle freely. It is a good idea to tie loose parts to the bicycle so they are not floating around the box. A bike shop will provide this service for you, but it may cost up to $35.
It 's not a bad idea to slightly deflat your tires. Depending on the cargo setup, a a plane's unpressurized cargo bay could result in a blowout.
Clothes, camping gear and accesories can be packed in the box around the bicycle, adding padding and utilizing free space. It's a good idea to not have small parts floating around the box as handlers may accidentally tear holes into the box. Make sure the total weight is under your baggage limit.
Airlines vary on whether they will charge for checking the bike box as baggage. Make sure you check with your airline to see their regulations and fees.
Preliminary research as indicated the following:
Alaska airlines and Frontier both charge $50. There may be extra fees if the bikes are more than 80" in overall dimensions (adding height, width, and depth of packing box).
The following airlines charge $80 if the bike exceeds 62" in overall dimensions:
- America West
- US airlines
- Continental
- United
- American
- Northwest
Potentially helpful links:
- Flying with your Bicycle: Guide to Airline Baggage Regulations
- Laguna Cyclery - Flying with your Bike