Definitely duct tape it. You could even buy a roll of pallet wrap and wrap it up. I'm sure the TSA would love either of those options, but thats what I'd do.

Another option is a couple longer ones like this in each direction.https://www.amazon.com/...a?crid=2ETU4IQKSTB4U[/url]

But I'd put 50 hole punches on either side, and run a really long shoelace through the thing, then tighten it up at the end like a nice piece of female hosiery.

I don’t think it’s a question of “will it fly” (by that I think you mean, will they let it go in the hold with improvised closure). I think any oversized case is subject to secondary inspection, at which point you can’t touch it and are leaving it to the agent to re-pack. I think the question should be if you are comfortable with the agent reassembling the case so you are satisfied that the contents are compromised.

Maybe put a bunch of zip tie sticky pads on it and zip-tie it shut?

-Scott

You just need to be absolutely sure that someone who doesn't really care at all about putting the case back together properly can do so with minimum time and effort involved. It has to be easier/faster to put it back together properly than to put it back together incorrectly. Whatever is the fastest/easiest way to put stuff back in the case, and get the damn thing closed back up is what TSA will do. They have absolutely no incentive to care what happens once the thing that isn't a bomb leaves their hands.

This is why zippers are great, up until they get broken. It's either zipped, or it's not. Pretty hard to f**k that up through not giving a damn/expediency.

Definitely don't tape/cling wrap the thing together. TSA will cut the tape off, and then *maybe* tape it back together. Maybe. Definitely not with the same level of care you did. Definitely not at all if their are even vestigial straps that they can kinda get to hold the thing together long enough to get it back to the airline, at which point it isn't their problem anymore. Or the airlines. At that point, it's no one's problem but yours, and you're SOL.

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Tech writer/support on this here site. FIST school instructor and certified bike fitter. Formerly at Diamondback Bikes, LeMond Fitness, FSA, TiCycles, etc.
Coaching and bike fit - http://source-e.net/ Cyclocross blog - https://crosssports.net/ BJJ instruction - https://ballardbjj.com/

If it were me I’d purchase the 5 pack of straps like the current ones - from Amazon. I think they are $18 for a pack of 5. Add 2 or 4 more.

That way TSA can open it and straps are easy for them to re-connect.

I also have some replacement zippers if you have a shop that can install it.

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Dan Kennison

facebook: @triPremierBike
http://www.PremierBike.com
http://www.PositionOneSports.com

I appreciate the suggestion. I’m probably gunna get some straps.

Also, I searched high and low for anyone who would replace the zipper. The only quote I got was $600.

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@floathammerholdon | @partners_in_tri

You might try this.

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Dan Kennison

facebook: @triPremierBike
http://www.PremierBike.com
http://www.PositionOneSports.com

I was unable to find similar straps online.

I just googled - Amazon buckle with strap.


Size: 1"×47"
^
1"×47°
1"×118"

($1.90 / Count)
prime

FREE Delivery
Tomorrow

Only 4 left in stock - order soon.
FREE Delivery

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Dan Kennison

facebook: @triPremierBike
http://www.PremierBike.com
http://www.PositionOneSports.com