So I just tried to make travel arrangements through the USAT travel desk, and apparently America West bought/got bought by US Air, so there are no more bike vouchers (they expired on the 15th of the month). Not sure if this affects current vouchers (El Paso camp attendees) or not, but might want to double check… What a pain… That was the only good part about USAT membership fees…
ugh.
what about the USA cycling United Airlines vouchers? $250 buys you a Gold membership and 10 or 12 vouchers…
I just built a box to fit my 53cm P3sl and mtn bike, small enough to pass as regular luggage with the wheels in a seperate box.
I’ll definitely look into that. Thanks.
And, sadly for me, no amount of fancy woodworking is going to get a 61cm frame within the limits… My bike doesn’t fit in the limits, I don’t fit in the seat… I hate travelling. 
Tai, could you give us a brief description of how you built the box? Materials? What are the airlines dimension limits for legal luggage? thanks for any help.
JD,
the limit for free airline travel is a total dimentsion of 62 inches, length + width + hieght.
Tai, see if you can post a pic of your new case. I am about to build a new case myself and would to look at some other creations for more ideas.
Hey Mike, I really need to snap some pics of the cases. They are made of Plasticor, 6mm for the frame box and 10mm for the wheels, 4’x8’ sheet for each box. They are cut and riveted together. The frame is a clamshell, basically a topless box lined with foam with a matching top. The top has side flaps which secure with velcro around the bottom, think a rectangle the same length and width as the bottom box with flaps on all sides the same height as the bottom box. You place the top over the bottom, press down the flaps (velcro is awesome) and secure with two long luggage straps that loop through slots in the box.
The wheelbox is a toploading design and as I built it after the frame box it’s a lot better and easier to construct design. I’ll post some pics soon. The actual dimentions are around 63in, but they are close enough. I haven’t been charged yet and I’ve flown 5 times this year. I check them at a skycap when possible and have big “TaiGraphx” “Graphic Design” decals all over them plus the prerequisite “Fragile decals”. If they really ask hard I tell them it’s a bike but fits under thier 62" luggage restrictions (make sure to check airline rules first of course).
I liked that idea of using one of those soft apparel bags to put your bike in, was that you who was doing that?
And, sadly for me, no amount of fancy woodworking is going to get a 61cm frame within the limits… My bike doesn’t fit in the limits, I don’t fit in the seat… I hate travelling.
If god had meant us to fly, he’d have given us shorter legs.
yes, that was me that has been using a garment bag for my frame, then a Wheel Safe for the wheels. I’d like to make something a bit more permanent now. I’ve been using the garment bag for about 4 or so years and it has held up very well. I looked very closely at Joe Bonness’ home-made bike box and while very good, his exact design is just a bit over my head as far as fabrication goes. I like the idea of using Plasticor, that stuff seems pretty inexpensive. I’m trying to picture what you have done. To make the topless box section, how did you assemble the four sides, I know you said they are riveted, did you use something on the inside seam to reinforce the joints?