My bike has S&S couplers (also known as S and S Machine Bicycle Torque Coupling) that allow it to be broken apart and packed into a normal-sized checked luggage box that flies at no additional charge. Getting it to fit is always a challenge, so I took photos to help me remember.

Your S&S-enabled bike will probably pack in a slightly different configuration, but you can still use this as a starting guide.

Step 1: Disassemble Bike

Take off the brakes, the rear deailleurs, the cranks, the handle bars, and fork.

Step 2: Fork and Front of Frame

Cover the frame with pipe insulation to protect the paint. Place the support bases, fork, and frame.

Step 3: Rear Wheel

Take the tires off both wheels, and place the rear in with the cassette facing down.

Step 4: Cranks

Wrap up the cranks and chain rings in a plastic bag, and pack them.

Step 5: Seat and Rear Frame

Place the seat and rear frame section.

Step 6: Front Wheel

Place the front wheel.

Step 7: Handle Bars

Fit the handle bars in.

Step 8: Tires and Finish

Squeeze the tires in. Place the top parts of the supports, add in the remains pieces, and carefully check if the box closes.

I always try the pack my bike the night before flying, to ensure I have time to do it properly.

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8 Comments

BtheBike

11 years ago on Introduction

Are there any diy S&S couplers ? those things are Way costly . Love to be able to do that with a similar cheaper pipe connector .

mwarren_us

12 years ago on Introduction

Hopefully the expiration of Steve-Frank Smilanick's patent 5586652Bicycle torque coupling in 2013 will make these couplers more readily available. They're extremely clever, but currently apparently only available to qualified bicycle frame builders. Which frame does your bike use? Also, are the bottom portions of the white supports attached to the bottom of the case somehow? Thanks for the clear pictures and detailed steps.