Flying with your bike doesn’t need to be stressful; with preparation and insider advice, you can breeze through the whole experience. Here are some of the most important issues that the road.cc editorial team has experienced and heard about, along with the best ways to tackle them. From packing tips to airline policies, here’s everything you need to know for smooth travels.

Bicycle insurance: compare quotes and find yourself a great deal to get your bike covered

Scicon Aerotech Evolution bike hard case
Scicon Aerotech Evolution bike hard case (Image Credit: Farrelly Atkinson)

Give yourself plenty of time to pack your bike

Packing your bike might take longer than you think, especially if it’s your first time with a new box, so don’t leave it until the day you’re flying. Life’s stressful enough. Some brands have detailed instructions to follow or even online videos to help you get it right (Scicon Sports shows you how to pack its Aerotech Evolution on its YouTube channel, for example).

Bonza Bike Box - inside.jpg
Bonza Bike Box - inside (Image Credit: Farrelly Atkinson)

You can be more carefree once you’ve done it a few times.

Mark your saddle height

Mark your saddle height on your seatpost before taking it out of the frame. A pen mark, paint or piece of electrical tape around the post will do the job.

It just makes life a little bit easier on the other side without the need to take a tape measure.

Pack carefully

Arm yourself with loads of bubble wrap, foam pipe lagging (available cheaply from DIY stores), and tape (electrical tape is perfect), and cover up everything you can – frame tubes, crank arms, handlebar, stem, seatpost… 

Scicon Aerotech Evolution bike hard case - open
Scicon Aerotech Evolution bike hard case - open (Image Credit: Farrelly Atkinson)

Pack everything carefully, and don’t forget that security could open your bike box to check what’s inside. There’s a good chance they won’t be as attentive as you when they repack it. The more you cover up, the less chance of damage from anything they leave loose.  

Check out the best bike boxes and bike bags 2025 

Be particularly careful with disc rotors (they can get bent), chainrings and the rear derailleur, all of which can be damaged quite easily. You’ll probably want to unbolt the rear derailleur from its hanger to avoid damage. It takes seconds. 

If your wheels attach to the box’s sidewall using quick-release skewers, use a skanky old set in case they get damaged or an end comes unscrewed in transit (we learned that the hard way). 

bike-box-alan-packing-1.jpg
bike-box-alan-packing-1 (Image Credit: Farrelly Atkinson)

Secure everything inside your bike box

Minimise the movement of everything inside your bike box by strapping it all in place as tightly as possible. The box could find itself upside down during the journey, so anything unsecured could rattle around in there.

Bike Box Alan Premium Bike Box 11.jpg
Bike Box Alan Premium Bike Box 11 (Image Credit: Farrelly Atkinson)

Don’t put your pedals loose on the bottom of the box and expect them to stay there, for instance. Either strap them to the side of the box (if that’s possible) or cover them in bubble wrap and stick them in a bag.

All bikes won’t fit in all boxes

Some bikes and boxes don’t work well together. Unusually large bikes and some mountain bikes can be tricky, and some time trial/triathlon bikes take a lot of disassembling. Plus, bikes with integrated (rather than removable) seat posts can be hard to accommodate.

Bike Box Alan Triathlon Aero Easyfit Bikebox
Bike Box Alan Triathlon Aero Easyfit Bikebox (Image Credit: Farrelly Atkinson)

As you’d expect, smaller bikes are easier to pack. You might get away with leaving the seatpost in the frame of a smaller bike, for example, whereas you’ll probably have to remove it from a larger frame.

2021 BikeBox Alan Triathlon Aero Easyfit Bikebox - velcro fixings.jpg
2021 BikeBox Alan Triathlon Aero Easyfit Bikebox - velcro fixings (Image Credit: Farrelly Atkinson)

If in doubt, check with the box manufacturer before spending your money.

Use spacers between the dropouts

Fit spacers between the dropouts of your frame and fork to prevent damage.

2025 Condor thru axle for spacer
2025 Condor thru axle for spacer (Image Credit: Condor)

You can buy dropout spacers like this one from Condor (£19.99), but plastic ones are fitted to bikes when they’re sent from the manufacturer to bike shops, so flutter your eyelashes a bit and they might give you a couple.

Use disc brake pad spacers

Shimano disc brake spacer - 1
Shimano disc brake spacer - 1 (Image Credit: Farrelly Atkinson)

Fit spacers to stop the disc brake pads from closing accidentally without a rotor in place. If you don’t have any, they’re not expensive but your local bike shop could have some spare ones floating around from boxed-up bikes that have been delivered. Give the mechanics a packet of biscuits and they might but a pair aside for you.

Should you deflate your tyres?

Most airlines require you to deflate your bike tyres before flying. Deflate them to at least 1 bar (14.5 PSI) below their maximum stated pressure (you might need to deflate them further to fit in the wheel spaces in your bike box). 

Is it necessary to let all the air out? No, but it’s not worth having that argument with check-in staff.

Something like Lezyne’s Digital Travel Floor Drive or a rechargeable Cycplus AS2 Pro Mini Bicycle Tire Inflator will make things easier on the far side. 

Add a tracking device

It’s unlikely that your boxed bike will go missing but, you know, it does happen. Lots of people add a tracking device to make a lost bike box easier to find.

Apple AirTag - 4 pack
Apple AirTag - 4 pack (Image Credit: Apple)

You’re probably up to speed on Apple’s AirTag, for example, and there are various bike-specific mounts out there.

> Innovative bike security solutions: from underground storage to high-tech tracking

Shokbox Orange Premium - 5.jpg
Shokbox Orange Premium - 5 (Image Credit: Farrelly Atkinson)

Some bike boxes come with integrated trackers. The Shokbox Premium that we reviewed has an optional GPS tracking system, for instance.

Can you carry other luggage in your bike box?

If your boxed bike is below the airline’s weight limit, you might be tempted to add extra luggage to the box. Just be aware that airlines often say that you shouldn’t do this.

For example, British Airways says, “Clothes and other personal items must not be packed in your bike cover or box. This may cause delays during security screening or mean your bike cannot travel.”

Look, we’ve all chucked extra stuff in there without any problems; just don’t tell anyone and don’t blame us if the airline kicks up a fuss.

You can use a cardboard box as a bike box

You can grab a cardboard delivery box from your local bike shop and use it as an alternative to a plastic bike box.

A cardboard box doesn’t provide the same level of protection as a rigid-sided bike box with a steel anti-crush pole in the middle, obviously, but it could save you quite a bit of money.

We know people who have been using them for years without any issues, although that’s not to say this will always be the case, of course.

Remove the rear derailleur

2024 Shimano GRX 12-speed Di2 rear derailleur
2024 Shimano GRX 12-speed Di2 rear derailleur (Image Credit: Farrelly Atkinson)

Many people remove the rear derailleur before travelling. That’s the safest option, and the one we’d recommend to avoid damage.

You could be okay to leave the rear derailleur in place if your bike isn’t resting on it (the frame is suspended) and there’s no danger of the side of the box or anything inside pushing against it, which could cause the hanger to bend. Chances are that the manufacturer of your bike box has specific advice on this. Take it!

If you’re in any doubt whatsoever, whip the derailleur off and wrap it up. It’s a simple job that takes no time.

Make sure your booking allows you to take your bike

If you’re flying with some companies, such as British Airways, you can use your hold baggage allowance (if you have it with the fare option you’ve chosen) to take a bike – although they ask that you let them know you’re intending to bring a bike as soon as you’ve booked your flight. Bear in mind that with BA Economy (with a checked bag), your bag can’t weigh more than 23kg. With Premium Ecomomy, you’re allowed two 23kg bags. Exceed the weight limit and you could find yourself paying more.

With many other companies, you’ll need to pay extra for a bike. With Ryanair, for instance, booking a boxed or bagged bike (weighing a maximum of 30kg) will cost £60 online, rising to £75 after you’ve made your initial booking or at the airport. That’s in each direction.

Easyjet take off
Easyjet take off (Image Credit: Farrelly Atkinson)

With EasyJet, you need to book a bicycle as ‘large sports equipment’ (up to 32kg). It’ll cost you £50 per flight if booked online, or £60 at the airport.

Check the weight of your packed bike box

Bear in mind that some bike boxes weigh much more than others and, as mentioned, different airlines have different weight allowances, so check in advance. Don’t assume the weight allowance will be the same as the last time you flew.

Park Tool DS-1 - 1
Park Tool DS-1 - 1 (Image Credit: Park Tool)

Rock up at the airport with a bike box that’s over the weight limit and you could incur excess baggage charges. Apart from anything else, that’s stress you really don’t need, so check it before you leave home.

Hanging scales are perfect for the job. If you don’t have any, your bathroom scales will do.  

If you can’t balance your bike box on the scales, weigh yourself, then weigh yourself again while holding your bike box off the ground and calculate the difference. 

Someone will ask what’s in the box

Even if your box has the outline of a bike moulded into the plastic or Bike Box Alan stickers plastered all over it, at some point a fellow traveller will ask you what’s inside.

That’s just the way it is, so get used to it. You could try travelling in full Lycra, but we suspect someone would still ask. 

Don’t pile stuff on top of your bike bag

Don’t stick your bike bag horizontally on an airport trolley and then heap the rest of your luggage on top or you’ll risk crush damage. Stand it upright to avoid trouble.

You’ll have to lift the bike box at some point

All bike boxes and most bags come with wheels, but you still have to lift them occasionally – over gravel driveways, into the back of the car, up steps at the train station, and so on. 

Read our bike bags and cases reviews

Even with a lightweight road bike inside, a fully packed bike box might weigh around 20kg. You can probably manage that for a short distance, but the size and shape can be awkward so you might want to have a trial run ahead of time just to be sure, and maybe even fashion yourself a shoulder strap out of a length of webbing if you have to carry it far. 

While you’re at it, a lanyard threaded through a latch can make pulling a bike box a whole lot easier.

Don’t carry tools in your hand luggage

The rules covering what you’re allowed to carry in your hand luggage at UK airports say no screwdrivers, pliers or “tools with a blade or shaft longer than 6cm”. 

Topeak Mini PT30 multi-tool
Topeak Mini PT30 multi-tool (Image Credit: Farrelly Atkinson)

Screwdrivers and wrenches/spanners are out too.

Gatwick Airport’s security advice says, “There are several items you can carry in hold luggage that you are not allowed to carry on board with you in your hand luggage. These include… tools (including multi-tools and penknives).”

We’ve forgotten about the multi-tool squirrelled away in a backpack pocket before and had it taken away. You’re better off avoiding the hassle and putting anything like this into the hold.

CO2 cartridges can be a hassle

The UK Civil Aviation Authority (CAA) says that you can carry: “No more than four small cylinders of carbon dioxide or other suitable non-flammable non-toxic gas per person and the water capacity of each cylinder must not exceed 50ml.”

For CO2, a gas cylinder with a water capacity of 50ml is equivalent to a 28g cartridge.

2022 Lezyne Twin Kit CO2 - cartridges.jpg
2022 Lezyne Twin Kit CO2 - cartridges (Image Credit: Farrelly Atkinson)

However, Gatwick Airport’s security advice says, “Some items simply aren’t allowed on planes at all. These include… any gas cylinders”.

The US Transportation Security Administration (TSA) says, “Except for personal medical oxygen cylinders, you can only carry an EMPTY compressed gas cylinder onboard a plane.” 

It says that CO2 cartridges aren’t permitted in either carry-on or checked-in bags.

The advice on CO2 cartridges is mixed, then. If you take them, be prepared to lose them.

Some airlines are more bike-friendly than others

Every airline publishes its bike carrying policy online; just Google ‘EasyJet bike’ (or whatever) to get the info you need, including size and weight limits, and charges.

Bear in mind that where additional fees apply, they’ll be charged in both directions. If you want to take your bike with Ryanair, for example, it’ll cost you £60 for the way out and another £60 for the way back (that’s at the time of booking; it’s £75 in each direction if you want to amend an existing booking).

British Airways currently allows you to take a boxed bike as part of your checked bag allowance, costing you no extra as long as it’s under 23kg. That weight limit isn’t a problem for a road bike, although you might struggle with some mountain bikes and heavier boxes.

The rules for e-bikes are different

Most airlines won’t carry electric bikes because of the risk of fire from lithium-ion batteries. If they do allow e-bikes, it’ll be up to a stated battery capacity.

Boardman ADV 8.9e electric road bike
Boardman ADV 8.9e electric road bike (Image Credit: Farrelly Atkinson)

EasyJet, for example, says: “Electric bicycles are not permitted for travel.”

British Airways specifically says, “You can take non-motorised, non-electric pedal bicycles or push bikes in a bicycle cover or box on our flights.”

Delta says, “Passengers are permitted to travel with lithium-ion batteries that contain a maximum of 160-watt hours per battery. Any lithium-ion battery containing more than 160-watt hours is prohibited from carriage on all passenger aircraft.”

That’s not particularly high. Whatever you do, check the airline’s rules before booking your ticket.

Oversized baggage can turn up virtually anywhere

Evoc Bike Travel Bag and stand - airport 2.jpg
Evoc Bike Travel Bag and stand - airport 2 (Image Credit: Farrelly Atkinson)

Sometimes there’s a designated collection point in the baggage reclaim hall for oversized baggage, sometimes your bike box will appear on the carousel with the rest of the bags and suitcases, sometimes it’ll be pushed through a door next to the carousel…

Don’t presume that the same airport will do the same thing every time.

Make sure your bike box(es) will fit into your hire car

Two standard bike boxes will fit inside a Fiat Panda with the back seats folded down, despite what they tell you at the car hire desk when they want you to upgrade. You’ll get a couple more bags in too, but things start to get dicey if you plan to take much more.

Check the dimensions of your bike box(es) against the dimensions of your hire car, just to be sure, and make certain that the boot opening is large enough.

Carrying your bike on a train or bus at the other end?

Check the rules. Sometimes it’s easy, sometimes it ain’t.

Consider having your bike delivered for you

Sherpr bike box-6.jpg
Sherpr bike box-6 (Image Credit: Farrelly Atkinson)

Companies like Sherpr will send a box for you to pack, then they’ll come and pick it up and deliver it to your final destination, saving you the hassle of lugging your bike around

The prices depend on your destination, the weight of the package, and how quickly you’d like it delivered.

Get insurance

Make sure your bike is insured for foreign travel or things could get expensive if anything goes wrong.

> Bicycle insurance — compare quotes and find yourself a great deal to get your bike covered

Damage can sometimes occur when you’re not with your bike, and it’s sometimes difficult to get anyone to accept liability.