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Slowtwitch-think Bike Case
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First original Slowtwitch thread, in preparation for first flight with bike.

Started the game Monday of building two bike cases for the trip to IMCOZ.

Goals:
Reusable
Cost under $150 each
Small enough to not look like a bike
Strong enough to stand on
Case weight under 10 lbs
Both cases same size
Five days construction time in off-work hours
Must hold Large Softride FasTT7, spare beam, two wheels and wheelcover, pump, running and biking shoes, wetsuit and tools
Must allow padding between parts to prevent scratching

Here's my concept


6 yards x 50" Kevlar cloth $100
6 yards x 48" fiberglass mat $60
6 yards x 38" fiberglass cloth $12
Gallon Polyester resin, hardener and finisher $40
2 x 2" by 24" by 48" Polystyrene foam sheets $12
6 yards x 50" x 1/2" foam padding $30

Looks like I'm going over budget. I haven't figured out the closure system yet. I have some strapping, buckles and handles that I may use.

If you've got any ideas or suggestions, please share them...quickly.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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The frame length was the length limiter.
The wheels were the height limiter.

Allowing for an inch of internal padding, the external layout ended up 27" x 38" x 8"


The second bike is a small P3 with 650c wheels, so it's a couple inches smaller each dimension. There's no trouble fitting it in a similar sized space.

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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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buy an akona case
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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I can't really help with your project but I bought this case for a recent trip.

http://store.mpgear.com/...mpetiton-cycles.aspx

I was able to find a store coupon code and get the case for ~$250.

It's a popular case on ST. I used curbside check-in both ways. On the way out they didn't ask what it was, and the bike was shipped for free. The return trip it cost me $50 (bike charge for Southwest)

It was just under 10lbs.
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Re: Slowtwitch-think Bike Case [IRONwolf] [ In reply to ]
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Akonas look like nice cases. Want to save $300, have a much smaller and more protective case, with wheels and backpack straps.
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Re: Slowtwitch-think Bike Case [TimBikeToo] [ In reply to ]
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Thanks. People seem to love those cases. I'm going for even smaller, cheaper, stronger, with wheels and backpack straps. At this date, I fear I wouldn't even be able to buy something in time for the flight Sunday.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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Each case will have two 4" deep halves.

I decided to round the ends and corners for strength, and to diminish the appearance of size.

Shaped the foam last night with a saw and file. Moving quickly, I didn't get a picture before I sealed it with epoxy paint.

Here is the plug for one half sealed:


Last edited by: DamonHenry: Nov 18, 09 14:32
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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Where do you live? I have a two bike case for sale:

http://forum.slowtwitch.com/...post=2500427#2500427
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Re: Slowtwitch-think Bike Case [UNC_Tri_Guy] [ In reply to ]
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Would you guys let the man do his thing! I want to see how this DIY project turns out. :-)
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Re: Slowtwitch-think Bike Case [kmill23] [ In reply to ]
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I agree. I want to see how his project turns out...anything that makes travelling with a bike easier and cheaper is a good thing. I like my Akona case, but there is always room for improvement.
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Re: Slowtwitch-think Bike Case [devashish_paul] [ In reply to ]
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Gathered the materials after work. The current plan is to make a Kevlar fabric hinge for the bottom, build adjustable straps and handle into the case weave for secure closure, and have a 4" width of Velcro around the entire seal. The Velcro should function like a zipper, but allow the edges of the shells to stay flush, thus stronger than a zipper would allow. The Velcro ends will tuck under, thus be covered by the buckles and handle, which will keep the ends secure during travel. This approach Velcro approach could suck, and will take me up to, and maybe over the desired budget in my game. Edge alignment could be an issue.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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I think its a pretty cool project, and even cooler that you are sharing it here.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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keep the posts coming please, I like projects like this. you need to finish this box ready and cured by this weekend?

Stefan
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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My initial read of your layout diagram has me concluding that you'll have to remove cabling from the handlebars to store the bike. Is that true?
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Re: Slowtwitch-think Bike Case [jyeager] [ In reply to ]
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The actual layout does not require cable removal, as shown in the layout photo.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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If you have the time keep us informed...and the pictures coming...very interesting!
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Re: Slowtwitch-think Bike Case [kus] [ In reply to ]
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Yes. I fly with them Sunday...I hope.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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Sweet Idea

I made one back in the day, then ditched it and bought one
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Re: Slowtwitch-think Bike Case [Elite_Tri] [ In reply to ]
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Any lessons learned that I should know about?
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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I was a cheap college student and used cardboard, very thick, but still cardboard.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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Love this concept, and the idea of what a finished product might look like. After reading this, I went out into the garage and laid several of our bikes (double diamond) out the same way, and it looks much more compact than the Iron case I currently borrow.

I see I would have to disconnect my front brake from the fork to remove the fork, which leads to this question: Is it easy to pull the front fork and reinstall each time? Do I have to worry about bearings coming out?

Thanks for sharing, and please do post more pictures in this thread as you proceed with construction and travel.

--------------------------------------


http://www.whydoesgodhateamputees.com/
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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One additional thing to keep in mind is TSA may open your bike bag. You'll want to make sure that packing it up and closing it is relatively easy to do.

Best of luck,
-Tim
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Re: Slowtwitch-think Bike Case [RichardS] [ In reply to ]
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In Reply To:
I see I would have to disconnect my front brake from the fork to remove the fork, which leads to this question: Is it easy to pull the front fork and reinstall each time? Do I have to worry about bearings coming out?


Bearings could be an issue with many headsets. I would suggest a cheap cable tie to keep them in the head tube. (actually might need 2 )
But that wouldn't be a hassle
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Re: Slowtwitch-think Bike Case [jyeager] [ In reply to ]
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Thanks! Good tip. Our bearings are sealed in cartridges, but it's still a great idea to hold everything in place.
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Re: Slowtwitch-think Bike Case [DamonHenry] [ In reply to ]
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In Reply To:
Thanks! Good tip. Our bearings are sealed in cartridges, but it's still a great idea to hold everything in place.


plus pack extra cable ties for the return trip. You'll have to cut them upon reassembly.
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