Re: [yak] Digest for yak@bikefriday.com - 13 updates in 1 topic

[Gary Keese]

Hi Roberta,

 

My BF NWT size large fits into the Samsonite 31 in spinner suitcase, so your bike should fit fairly easily.

 

But your issue may be weight. .The US airlines I have flown allow up to 50 lbs (about the same in Europe). My bike and case (with a few accessories TSA does not allow as carry ons - U-lock, bike tool with built in knife, etc) push me close to the 50 lb limit. 

 

I'd suggest you weigh your bike and the listed weight of the suitcase to see if that's below 40 lbs.  I have carried on heavier (but TSA allowed) parts like pedals and saddle to stay under the 50 lb. limit.

 

Good luck and enjoy your BF. They are great travel bikes and open up many wonderful adventures.

 

Gary

Seattle, WA

 

 

On 12/17/2025 5:57 PST y...@bikefriday.com wrote:

 

 

y...@bikefriday.com

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• Suitcase size options - 13 Updates

Suitcase size options

R <rcha...@gmail.com>: Dec 16 07:25PM -0800 Hello, fellow Bike Friday owners. I “know” many of you from the RBW and I-Bob forums. Last year I purchased a used 54 cm ETT pocket rocket. I’ll be doing a write up shortly to introduce myself and my Pocket Rocket.   I plan to do more airline travel, mostly on frontier airlines. They have they do have special pricing for bicycles at $75 each way. Still if I could get my bike in a standard size and under 40 pound suitcase, I can check the bag and it will cost me nothing, as I’m a “member.”   Before I waste too much time searching and buying the wrong size suitcase (I did do a search on the forum) does anybody think that there’s a suitcase that would be small enough that I can get my bike into so I don’t have to pay the fees? Or would it just be trial and error buy a bag that is less than 62 inches and put my bike in there and see if I can get it to fit?   I did see some discussions about packing the bike in cardboard, but I’m really looking to put it into a suitcase.   Thank you so much   Roberta Philadelphia   Frontier airline restrictions *Checked bags *must not exceed *62 linear inches* (length + width + depth) and must weigh *40 lbs or less*.   Oversize or overweight bags may incur additional fees: • *41–50 lbs*: +$75 • *51–100 lbs*: +$100 • *Over 100 lbs*: Not accepted • *63–110 linear inches:* +$75

R <rcha...@gmail.com>: Dec 16 07:29PM -0800 Well I hit the send button before I was finished editing   Here’s a picture of my pocket rocket with new 1 3/8 inch maxxis tires (highly recommended better than the skinnier original tires. Thanks John for the suggestion) and Milano handlebar. I think everything else is more or less standard.   Roberta Philadelphia   On Tuesday, December 16, 2025 at 10:25:28 PM UTC-5 R wrote:

F6515 <fjk...@gmail.com>: Dec 16 07:53PM -0800 Here's what I got for my New World Tourist   https://www.amazon.com/gp/aw/d/B005SLEEFI?psc=1&ref=ppx_pop_mob_b_asin_title   Sent via BlackBerry Hub+ Inbox for Android   From: rcha...@gmail.com   Sent: December 16, 2025 7:25 PM   To: y...@bikefriday.com   Subject: [yak] Suitcase size options   Hello, fellow Bike Friday owners. I “know” many of you from the RBW and I-Bob forums. Last year I purchased a used 54 cm ETT pocket rocket. I'll be doing a write up shortly to introduce myself and my Pocket Rocket.   I plan to do more airline travel, mostly on frontier airlines. They have they do have special pricing for bicycles at $75 each way. Still if I could get my bike in a standard size and under 40 pound suitcase, I can check the bag and it will cost me nothing, as I'm a “member.”   Before I waste too much time searching and buying the wrong size suitcase (I did do a search on the forum) does anybody think that there's a suitcase that would be small enough that I can get my bike into so I don't have to pay the fees? Or would it just be trial and error buy a bag that is less than 62 inches and put my bike in there and see if I can get it to fit?   I did see some discussions about packing the bike in cardboard, but I'm really looking to put it into a suitcase.   Thank you so much   Roberta   Philadelphia   Frontier airline restrictions   Checked bags must not exceed 62 linear inches (length + width + depth) and must weigh 40 lbs or less.   Oversize or overweight bags may incur additional fees:   • 41–50 lbs: +$75   • 51–100 lbs: +$100   • Over 100 lbs: Not accepted   • 63–110 linear inches: +$75   --   another great conversation from the Bike Friday Yak!   ---   You received this message because you are subscribed to the Google Groups "Bike Friday Yak!" group.   To unsubscribe from this group and stop receiving emails from it, send an email to yak+uns...@bikefriday.com.   To view this discussion visit https://groups.google.com/a/bikefriday.com/d/msgid/yak/5bcec670-ba60-47b4-a048-8cc36bdd4f24n%40bikefriday.com.

Ray Chong <xina...@gmail.com>: Dec 16 08:50PM -0800 That's the one that Bike Friday sells (or did, I have not gotten one recently). F'lite 31 (inches), also known as the Aeris Comfort 82 (cm). I like it a lot. It is sturdy and relatively easy to roll. One thing you'll want to make sure to have is a center support to prevent the case from squishing in when under load (the walls are somewhat flexible). That's the thing with the metal disk in this pic. BF includes one in their travel case kit but you should be able to kluge one from parts at your local hardware store.   -Ray

R <rcha...@gmail.com>: Dec 17 06:24AM -0800 Thanks. I did see that one during my research, but Frontier airlines is VERY strict and includes the wheels and handles. F'Lite's overall dimension is 32.67" x 23.48" x 13.77", or 69.92" linear inches, which is oversized.   I might need to buy the travel kit from BF, but would love a slightly smaller overall dimensioned case, if possible.   Roberta Philadelphia

F6515 <fjk...@gmail.com>: Dec 17 07:31AM -0800 I think your model might be smaller than mine. On my last trip last month, Alaska let me slide on the way out but dinged me the 100 dollars on the way home for overweight. It is the suitcase BF recommended. I did get the travel kit. A bit pricey but convenient with labeled felt bags and plastic protectors and the crush protector. Although i had to reinforce the protectors flanges with wraps of gorilla tape   Sent via BlackBerry Hub+ Inbox for Android   From: rcha...@gmail.com   Sent: December 17, 2025 6:24 AM   To: y...@bikefriday.com   Cc: fjk...@gmail.com; rcha...@gmail.com   Subject: Re: [yak] Suitcase size options   Thanks. I did see that one during my research, but Frontier airlines is VERY strict and includes the wheels and handles. F'Lite's overall dimension is 32.67" x 23.48" x 13.77", or 69.92" linear inches, which is oversized.   I might need to buy the travel kit from BF, but would love a slightly smaller overall dimensioned case, if possible.   Roberta   Philadelphia   On Tuesday, December 16, 2025 at 10:53:59 PM UTC-5 fjk...@gmail.com wrote:   Here's what I got for my New World Tourist   https://www.amazon.com/gp/aw/d/B005SLEEFI?psc=1&ref=ppx_pop_mob_b_asin_title   Sent via BlackBerry Hub+ Inbox for Android   From: rcha...@gmail.com   Sent: December 16, 2025 7:25 PM   To: y...@bikefriday.com   Subject: [yak] Suitcase size options   Hello, fellow Bike Friday owners. I “know” many of you from the RBW and I-Bob forums. Last year I purchased a used 54 cm ETT pocket rocket. I'll be doing a write up shortly to introduce myself and my Pocket Rocket.   I plan to do more airline travel, mostly on frontier airlines. They have they do have special pricing for bicycles at $75 each way. Still if I could get my bike in a standard size and under 40 pound suitcase, I can check the bag and it will cost me nothing, as I'm a “member.”   Before I waste too much time searching and buying the wrong size suitcase (I did do a search on the forum) does anybody think that there's a suitcase that would be small enough that I can get my bike into so I don't have to pay the fees? Or would it just be trial and error buy a bag that is less than 62 inches and put my bike in there and see if I can get it to fit?   I did see some discussions about packing the bike in cardboard, but I'm really looking to put it into a suitcase.   Thank you so much   Roberta   Philadelphia   Frontier airline restrictions   Checked bags must not exceed 62 linear inches (length + width + depth) and must weigh 40 lbs or less.   Oversize or overweight bags may incur additional fees:   • 41–50 lbs: +$75   • 51–100 lbs: +$100   • Over 100 lbs: Not accepted   • 63–110 linear inches: +$75   --   another great conversation from the Bike Friday Yak!   ---   You received this message because you are subscribed to the Google Groups "Bike Friday Yak!" group.   To unsubscribe from this group and stop receiving emails from it, send an email to yak+uns...@bikefriday.com.   To view this discussion visit https://groups.google.com/a/bikefriday.com/d/msgid/yak/5bcec670-ba60-47b4-a048-8cc36bdd4f24n%40bikefriday.com.

Scott McMahon <scot...@gmail.com>: Dec 17 07:54AM -0800 Hi Roberta, Fear not. There are suitcases for your situation. My wife and I have pocket Rocket pros. We've flown with them many times, but not with Frontier. We purchased our bikes with travel cases in the late 90's or early 00's. At that time BF was providing Carleton brand suitcases, and I think they would probably comply with Frontier's specs. They are kind of barebones plastic clamshell affairs that come in a variety of colors (ours are yellow). I measured mine the other day and it was 29" High X 23" Wide X 10" Deep, (exterior dimensions, including wheels.)   The suitcase has two wheels and you drag it around the airport in the upright position while holding the towing handle up off the ground on one end (and bearing half of the weight) while the wheels, on the other end follow. A much less pleasant experience, unfortunately, than you would have with a 4 wheeler that can stand up on it's own, bear all it's own weight on the wheels and be pushed in any direction, but it's workable.   The bikes fit inside nicely, although we can't just throw them in any old way, I had to play around a bit until I figured it out, and when I did, I took photos to get it right thereafter. (I'll attach a couple of my photos to this post.) We have drop bars and always bring rear racks and panniers. Looks like you have flat bars and no rack, so packing might be a little less fussy for you. In any case, I wouldn't worry about getting your bike in a suticase of this size. The bike was, literally, made for it.   Your bigger problem may be the weight limit. Most airlines allow 50 lb suitcases, some 44 (20 kg). Frontier is unique in my experience in limiting you to 40. Our Carletons weight 11.4 lbs empty. You can weigh your bike and do the math. Your bike should be under 28.6 lbs, but you won't be able to put much else in the suitcase with your bike, (like bike shoes or bags or what have you.)   I've been looking for more luxurious travel cases (bigger, 4-wheeled) for us to use and have found that there is a surprisingly good selection of used suitcases on Craig's List, so I'd suggest looking there. If I find what I'm looking for, I'll be sure to put our old cases up for sale, (and try to remember to avoid flying Frontier after that).   The attached photos show my bike packed in with rear rack (unattached to bike) and aero bars. Sorry I don't have photos of the cases on their own. Maybe when I get home, (we're away on a Christmas trip and won't be back till new year), I'll get a photo of the outside of the case for you.   Scott McMahon

Scott McMahon <scot...@gmail.com>: Dec 17 08:45AM -0800 Hi again Roberta,   FYI, I don't usually bother with a lot of the padding that came with the bikes and haven't gotten a lot of scratches. I have the crush protectors, and use them, although not shown in the photos attached to my last post. If you don't have them you can use a piece of cardboard, about 10" wide (or whatever matches your suitcase's internal width) and roll it up into a cylinder about 1.5-2" diameter, then run a layer of tape around it to hold it together and prop it up through the spokes and frame to keep the sides of the suitcase from collapsing in the middle (in case a baggage handler sits on it.) I also usually roll up a similar cardboard cylinder to put between the frame and the suitcase under my front derailleur (see photos for what the derailleur looks like when packed.) This keeps the derailleur from banging up against the side of the suitcase in transit. (In the photos, I didn't have the cardboard cylinder there, yet.)   Also, I notice that I have removed the cranks and the rear derailleur on my bike for packing. Something I've been doing for a long time now. I find those parts are easy to disassemble and reassemble with minimal tools, and it makes packing much easier and protects those parts from damage, but you shouldn't have to do that to get your bike into the suitcase. For me, it's as easy to remove the cranks as to remove the pedals, (and if you take off the cranks you no longer have to unscrew the pedals,) but without cranks it packs flatter and the chainrings can't get bent. Note: I have the kind of cranks that are "self-removing." so a slightly longer than normal 6 mm hex wrench is all I need to bring for the job. I do use some of the padded pockets the came with the bike to protect the cranks and derailleur from the frame and vice versa.   Also FYI, if you're wondering what that electronic board in my spokes is, it's a set of strobing lights from "Monkeylectric" that forms light patterns (like flashing hearts) in the wheel, as it spins.   Scott   On Wednesday, December 17, 2025 at 7:54:18 AM UTC-8 Scott McMahon wrote:

John Thurston <y...@thurstons.us>: Dec 17 09:18AM -0900 What are the exact Frontier limiting-dimensions?   On 12/17/2025 5:24 AM, R wrote:   -- John Thurston Juneau, Alaska

John Thurston <y...@thurstons.us>: Dec 17 10:20AM -0900 Before the Carlton case, Bike Friday used a Samsonite 'Oyster' . When I measure that old case 'box style' (building a virtual box around it, so the faces of the box touch the extreme edges like the wheels and the top of the handle), I get 29x23x10 inches. Summing those, I get 62 inches which meets the limit mentioned at the bottom of your first email. If I were to measure it using a flexible girth-tape along its actual surfaces, it would come in less than 62 inches.   As the ancient Samsonite comes in at 62 inches, I'm not even going to bother pulling the newer/larger Carlton down off the shelf to see what it measures.   I expect your 54cm bike can be made to fit into the ancient Samsonite. But   1. can you find one? 2. do you want to do the disassembly required to make it fit?   I recently scored an almost-new Samsonite at a local thrift-shop, and bought it as a backup to my 90's vintage case. My sister recently found two more, in good condition, at a thrift-shop. So they are out there, but you must hunt for them.   The 'case spreader' or 'crush protector' is an important piece. It is made from a bit of electrical conduit and two flanges at either end. It looks like a light weight dumbbell. It needs to be made to fit your particular case. You assemble it by dropping one flange loose in the bottom of the case, putting the folded bike on top, and then inserting the other bit down through the bike to mate with the flange you dropped in. The bit of conduit is threaded into the upper flange, and is sanded down to taper-fit into the bottom flange.   My case (original from about '97) is pictured here. My bike is inside, with the tools I want to re-assemble it. This is just as it came off the airplane a couple of months ago. On my digital bathroom scale, it measures a repeatable 40.0 lbs. An annotated picture <https://flic.kr/p/2fEebzt> from a few years ago is available on flickr.   Fitting my bike in is a challenge. I can get the 50mm tires in, but it is tight. Packing 44mm tires is a lot easier. I have un-cut 420mm bars and they just fit. I could not go wider or deeper. When I had cut bars (separable at the center), the packing was easier. I have a 50t chainring, and the crank must be removed for the suitcase (more on that later). When I used a 42t, packing was a lot easier. After arriving once with a bent chain, I now remove the chain when packing for my outbound-journey*. After arriving once with a bent derailleur hanger, I now demount the derailleur for my outbound-journey.   I have fitted one-key release bolts <https://www.universalcycles.com/shopping/product_details.php?id=49519> to my crank so I don't need to carry a crank extractor. I have trimmed the end of my seatpost and it packs MUCH better.   My old Llama is a 'right swing' (i.e. the rear wheel swings to the right of the fork during folding). Your newer rocket is probably a 'left swing'. This will protect the derailleur much better, but means the photos of my old bike in the case of of less value.   * When returning home, I may leave these in place as I can easily correct any shipping damage when I'm in my garage.   -- John Thurston Juneau, Alaska   On 12/17/2025 6:54 AM, Scott McMahon wrote:

John Thurston <y...@thurstons.us>: Dec 17 10:22AM -0900 oops. I found them 'after the sig' in the original message   "Checked bags must not exceed 62 linear inches (length + width + depth)"     -- John Thurston Juneau, Alaska

John Thurston <y...@thurstons.us>: Dec 17 10:28AM -0900 And if you are going to travel with it, quick release pedals are nice to have!   This isn't just for fitting into the suitcase. Quick release pedals also make it easier to fit the un-folded bike into a vehicle, or hotel room. It makes it easier to walk alongside while pushing the bike. It also makes it easy to switch among flat/spd/toke-lip pedals.   There are lots of removable pedals out there. In my experience, NONE of the brands play nicely with others. So if you start with quick-release from company A, you are stuck with them. I chose the MKS product, and have them on almost all of my bikes (including the non-folding bikes).   -- John Thurston Juneau, Alaska   On 12/17/2025 7:45 AM, Scott McMahon wrote:

R <rcha...@gmail.com>: Dec 17 02:10PM -0800 So much great information here! I'll be pouring over it later tonight. I'm hopeful this will be possible. I'll be shopping at CL, "Home Goods" and Thrift stores for a potential case. CL has been awful lately for selling items, but perhaps that will work in my favor for buying a suitcase. THANK YOU for instructions on how to make the crush protector. That item seems like a "must have."   I put MKS foldable pedals on bike to make it easier to deal with car and BF "bag" travel. But, it's nice to see other options if they are still too wide. I'll have to weigh the bike, but I've tried to keep it as light as possible. I don't even have a kickstand.   Roberta Philadelphia   On Wednesday, December 17, 2025 at 2:28:38 PM UTC-5 John Thurston wrote:

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