Transporting cycle on a flight in India

               Here I would like to share my experience of transporting a cycle with me in a domestic flight in India. I traveled from Kochi to Delhi. I tried to dismantle my cycle ( Hercules Act 110) as much as possible so that the luggage will not be over sized. Anyway I always had the backup plan of sending it in train if the flight authorities deny.

               I got a cardboard box and two extra axles from a cycle shop. After dismantling the cycle, I cut the extra space of the box. After packing the size was about 130 x 70 x 30 cm and weighed 18 kg. The Air India airport staff were kind enough to give concession for that extra 3 kg. Also they gave extra care to the package on my requisition and applied a ' Fragile' label on it. Fortunately there was no damage during transportation. 

The package

The Fragile label for extra care

Side view

Security checked

Parts brown taped to prevent rolling around

Out of the box

Tire off rims to decrease box height. 

       Tires were removed from rim so as to decrease the height of the box. Also the tires were placed at sides of the frame inside the box for extra cushioning.Some extra foam was also kept inside the box over sharp parts and rear derailleur.

         Front and rear forks were fixed with extra axles to prevent distortion. All of this dismantling can be done with minimal tools. 15 no spanner and L keys of two sizes. A star shape screwdriver is optional and I used a flat screw driver for fixing tires over rim.

                                                                    

 

Minimal tools 

Final product