My wife took this photo in 2019 when we were traveling to Nagoya for the Japan 70.3 Ironman. Most Ironman triathletes have been to some remote places for a race, and when the travel is difficult the last thing you need is issues with oversized luggage, a missing bike bag, or broken gear. To that end, I’ve put together a summary of my tips for traveling with your bike to make sure it arrives safely and is ready to race.

I have traveled so much with my bike that it now feels weird rocking up to the airport without it. These are some lessons learned and the things that I always do to ensure my bike is prepped, packed, and in working order for a destination race.

——

Choosing a bike container

First things first, let's talk about choosing the right bike container. You have a few options here. If you're on a budget, a cardboard bike box from your local bike shop or an airline can do the trick. They're lightweight, but you'll need to remove pedals, saddle, handlebars, and wheels, and add some foam or bubble wrap for protection. The downside is that they're not super durable and won't last through multiple trips. The times I used cardboard boxes, I would also pack a roll of gaffa tape so any tears can be patched to ensure the bike makes it home in its box! Always draw arrows or use gaffa tape to show which way is up for baggage handlers to follow.

If you're looking for more protection, a hard-shell bike box is the way to go. These babies are sturdy and can handle some rough handling during transit. However, they tend to be heavier and require a bit more mechanical know-how to disassemble and fit your bike inside. They are also bulky and do not fold down so they take up lots of storage space when not in use.

For the simplest option, you can go for a soft-shell bike bag. These are easy to remove and reassemble, but they come with the highest price tag. Just make sure to pad your bike frame really well with bubble wrap or foam since they offer less protection. And keep in mind that these bags usually have wheels so baggage handlers sometimes lay them (and the cardboard bike boxes) sideways on the carts, and could load other bags on top. This given, assume the worst and wrap your bike with enough padding to withstand something heavy placed on top. Soft cases have a built-in frame to protect your forks, but if you do get the cardboard box from a bike shop, you can ask them to throw in some fork jammers - pieces of plastic that will stop your fork from snapping if there is any sideways pressure. 

Packing your bike

Once you've picked your container, it's time to pack up your bike. Now, here's a vital tip: take pictures of your bike before packing it. This will serve as evidence in case any damage occurs during transit. If your bike is covered in grime from your last ride, give it a clean before packing it down as it will be easier to handle, pack down and rebuild, and will make it easier to identify any potential damage. And as they say, a clean bike is a fast bike!

Before you start packing, take a moment to mark your seat post height and handlebar position using a tiny amount of whiteout, nail polish or electrical tape. This way, you can easily set them up the same way when you reassemble your bike. And don't forget to remove any accessories like lights or Garmins. Then get started by removing the pedals, saddle, seatpost, wheels, and handlebars. Wrap them up in bubble wrap or foam to prevent any damage. I personally use cheap hollow pool noodles to protect the main triangle and forks of my bike as they sit perfectly around a frame, and offer a lot of padding but are also lightweight and reusable. 

Before you leave for your trip, take a moment to inspect your bike's bolts and tools. Look out for any signs of rust or wear. It's crucial to ensure that everything is in good working order, as you don't want to encounter any issues while reassembling your bike. Replace any rusted or stripped bolts before flying to avoid any headaches later on.

Keep in mind that bike pumps can be quite large and usually don't fit inside a bike box or bag. If you're short on weight allowance or space and you’re not going to pack a bike pump, consider deflating your tires slightly and leaving them at a manageable pressure (50-60 psi). This way, you can still ride your bike to a nearby bike shop or the race expo upon arrival to inflate them properly. Alternatively, if you can squeeze the pump into your packing, make sure it's well wrapped up to avoid any damage.

Navigating the airport madness

Different airlines have different rules when it comes to transporting bikes. Make sure to check with your airline about their policies, fees, and any weight and size restrictions for bike containers. It's always better to be informed in advance and avoid any surprises at the airport. I knew American triathletes who used to travel with their bikes in hockey bags in pieces to avoid the $200 USD bike box fee, as hockey sticks were covered under “sporting goods” but bikes weren’t for that particular airline. Who says that all sports are equal!?

When the big day arrives, give yourself plenty of time at the airport. Checking in a bike box can take some extra time and attention so look out for any signs or instructions pointing you to the right check-in area. Some airlines even have separate lines or counters for oversize items, which can potentially speed things up for you. Virgin Airlines allows you to check your bike box in at the oversize counter, avoiding the dread of dragging your bike and luggage through a 30-minute queue.

On one important note: you can't fly with CO2 canisters. They're considered hazardous materials and are not allowed on flights. So, before you head to the airport, double-check your saddle bag and remove any CO2 canisters to avoid any surprises at the security checkpoint. I learned this the hard way when I was pulled out of my seat on a fully boarded plane to go back through customs and check-in to open my bag and declare a canister in my luggage. Note that certain bike tools aren’t allowed either. A friend had an interesting and sweaty conversation explaining a chain whip to airport security. 

Once you've landed at your destination, your bike should be delivered to the oversized counter on the other end. These are usually nowhere near the baggage carousel, but I have found that oversized luggage comes off the plane first, so get your bike first and chances are that you won’t have to wait half as long for your actual luggage. If your bike case is easy to open, take a quick look to check the bike is yours as the cases all tend to look the same. It is also important to do a quick check for any damage so it can be raised immediately. 

Reassembling your bike

Now that you have retrieved your bike and it’s made it to your race accommodation in one piece, it's time to start reassembling. Make sure you have the necessary tools handy; a torque wrench with allen keys, a pedal spanner, and a tiny bit of grease should be enough to put your bike back together. Take your time to do it right – you don't want any loose bolts or crooked handlebars on race day. Double-check that everything is securely attached and properly aligned by going for a quick spin to check the brakes and wretch on the handlebars to ensure it feels and reacts the same as it did before it was packed.

Common mistakes to avoid

Now, let's address some common problems and precautions. First, make a checklist of all the tools and components you need to pack and check off before placing them in the box. This way, you won't leave anything behind or have that nagging feeling that you forgot something important without any means of checking, unless of course, you unpack and re-pack.

Also put things like seatpost collars, shims, bolts, and pedals in a sealed sandwich bag. This bag can go in your carry-on or in a pocket within the bike box or bag. It keeps everything organised and prevents any disappearing acts. I knew someone who threw their pedals in a bike box with holes for handles and only found one pedal on the other end. Fortunately, they were able to buy a new set of pedals in time, but it was an extremely stressful experience that isn’t conducive to good pre-race preparation.

——

By following these tips and taking the necessary precautions, you can travel overseas with your bike for a triathlon with a little less worry about its safety. Remember to choose a reliable bike container, prepare your bike properly, check airline policies, arrive early at the airport, and reassemble your bike with care. With your bike in good hands, you can focus on your race and make the most of your triathlon experience. So, go ahead and embark on your triathlon adventure with confidence, knowing that your bike will be ready to roll when you reach your destination.