How to Pack Your Mountain Bike in a Travel Bag

Packing your bike properly is the difference between arriving ready to ride and arriving with a repair bill. This guide covers everything from basic disassembly to pro tips that'll make baggage handlers less likely to treat your bike like a crash mat.

Before You Start

Tools You'll Need

Workspace Setup

• Clear floor space of at least 2m x 2m
• Good lighting (you'll be checking small details)
• A clean surface to lay parts on
• Your phone for taking "before" photos (trust us)

Step 1: Remove Pedals

Pedals stick out and are the first thing to get damaged or damage your frame inside the bag.

The Process

1. Position the crank arm forward (3 o'clock position for the side you're working on)
2. Right pedal: Turn counter-clockwise to loosen (normal thread)
3. Left pedal: Turn clockwise to loosen (reverse thread!)
4. Use the frame for leverage—push down while holding the opposite crank

Step 2: Remove Wheels

Quick Release vs Thru-Axle

Most modern MTBs use thru-axles. If you're unfamiliar with your specific axle type, check your bike's manual or search "[your bike model] axle removal" on YouTube.

The Process

1. Shift to smallest cog (rear wheel) for easier removal
2. Open quick release or loosen thru-axle
3. Lift frame, let wheel drop out
4. Critical: Install rotor spacers immediately to protect disc brakes

Step 3: Handlebars

You have two options here: loosen the stem and rotate bars, or completely remove them. Most soft bags work with rotated bars; hard cases often need full removal.

Option A: Rotate Bars (Soft Bags)

1. Loosen the stem faceplate bolts (usually 4mm Allen)
2. Don't fully remove—just enough to rotate bars 90°
3. Bars should point along the frame, not sideways
4. Wrap grips and levers with bubble wrap

Option B: Remove Bars (Hard Cases)

1. Remove stem faceplate completely
2. Carefully lay bars beside frame
3. Keep cables connected if possible
4. Secure loosely with velcro or zip ties

Step 4: Rear Derailleur

The derailleur hanger is the most vulnerable part of your bike. A bent hanger means no shifting. Protect it religiously.

The Process

1. Shift to smallest cog before wheel removal
2. Remove derailleur bolt (usually 5mm Allen)
3. Tuck derailleur inside rear triangle
4. Wrap in bubble wrap
5. Secure with velcro strap (not zip tie—you need to undo this)

Step 5: Frame Protection

What Needs Protection

• Downtube: Foam pipe insulation or pool noodle
• Top tube: Same treatment
• Head tube: Bubble wrap around bearings area
• Dropouts: Cardboard covers (make from a box)
• Chainstay: Wrap where chain might contact

The goal is preventing any metal-to-metal contact and cushioning against impacts. Over-protect rather than under-protect—it's your bike.

Step 6: Loading Sequence

Order matters. A well-loaded bag rolls smoothly and protects better.

Soft Bag Loading Order

1. Frame goes in first (most bags have a cradle or strap system)
2. Wheels on either side of frame (rotor sides facing out)
3. Fill gaps with soft items: helmet, shoes, knee pads
4. Pedals in a cloth bag, tucked in a corner
5. Tools and small parts in a ziplock, in an outer pocket

Hard Case Loading

1. Follow case manufacturer's instructions (they're optimised)
2. Frame in designated cradle
3. Wheels in wheel pockets
4. Fork in fork holder if available
5. Straps snug but not crushing

Step 7: Final Checks

Weigh your packed bag at home. Airport overweight fees are typically $65-150 per flight. A $20 luggage scale pays for itself immediately.

At the Airport

Check-In Tips

• Arrive early—sports equipment check-in can take longer
• Pre-book your bike as sports equipment online if possible
• Have booking confirmation ready showing pre-paid bike fee
• Be friendly—check-in staff have discretion on weight enforcement

Do "Fragile" Stickers Help?

Honestly? Probably not much. But they don't hurt, and some riders swear by them. More useful: watch your bag go on the belt and note any rough handling.

Documentation

Take photos of your packed bag at check-in, including:

• Overall bag condition
• Any existing marks or wear
• The bag going onto the conveyor

This is your evidence if anything goes wrong. Airline liability is typically capped around $1,700 AUD regardless of your bike's value.

You're Ready

First time will feel slow and stressful. By your third trip, you'll have a system dialled. The key is practice—do a dry run at home before your first real trip.

And remember: a well-packed bike in a borrowed bag beats a poorly-packed bike in an expensive case. Technique matters more than equipment.