Homemade Bike Case

How to make your own hard case by Mark S

There are many options for flying with a bike. Triathlon in Tokyo has a whole webpage on the rules for different airlines and the various bike bags and cases avaiable. Here I will describe how to make your own hard case using a rinko bag and a cardboard bike box cut to fit inside the bag. I use an Ostrich MTB rinko bag (MTB 輪行袋) which requires you to remove both front and back wheels. This has thicker fabric than regular rinko bags and lasts very well. I then get a used cardboard bike box from my local bike store. Many bike shops are happy to give these away as they only put them out for recycled waste. 

To fit the box, I just lay the rinko bag on top of the box, draw around it with a marker pen, and then cut it to shape with a box cutter. You need to use use lots of gaffer tape to make a rigid box. 

I find it best to remove both wheels and put them in wheel bags which are padded with thick bubble wrap. Remember to let air out of the tyres for flights. I remove the saddle and seat post and protect the carbon seat post with a tube of cardboard. I remove the rear derailleur and hanger together, wrap them in bubble wrap, and secure them inside the frame with reusable cable ties. I also make a half-moon of cardboard to wrap around the bottom half of the chain set. Finally, I remove the handlebar & stem and cable ties them to the frame. I use pipe insulation as padding to protect the frame.

The Ostrich MTB bag is shaped to fit the frame, so there is one obvious way for the bike to go into the bag. I put one wheel either side of the frame, and then use things like my wetsuit, inflated swim buoy, and “inflated” bike packing bag as packing around the frame. 

I use two brightly coloured roof rack straps around the bag. And to help with transporting the bag, I fix sets of plant pot casters to the underside with the straps. You can buy these casters for 220 yen at larger Daiso 100 yen stores. Before checking in the bike, I remove the casters and put them inside the bag.

This is a cheap, lightweight option which gives you lots of flexibility, especially if you are cycle touring. You can discard the cardboard box and just ride with the rink bag. The case is also quite compact, so it will fit in the boot of a regular Japanese taxi.