The hard part was making the bike frame sit in the case! Move the frame one way, and it sticks out to far, move it another way and you can’t close the case. Then a wheel or some other part would move. It took me several iterations to get it just right. Somehow, when I re-packed to come back home nothing quite fits the same? I think with good practice it would be a no brainer?
And my head I’d be scratchin’ while
my thoughts were busy hatchin’
If I only had a brain.
I used lots and lots of padding. I found it easier to use lots of shop rags, since they have a dual purpose. In addition, I still had these great baby diapers changing blankets, which were nice for large padding, and gave you something to lay parts out when working. It was tougher when I got to my destination, since I didn’t have a nice bike stand to work with.
I put all the small parts in a little box, it makes it much easier to keep track of things. Of course on the way out, they opened the case for inspection, and somehow the little box opened partially so I had little bolts floating around in the case. On the way back home, I used rubber bands around the box, so that it would stay shut. And of course don’t forget the proper tools for putting it together and taking it apart! When I was done, the entire bike, tools and case came in at 47 lbs., so to meet the 50 lbs. weight limit you may need to carry the tools in other baggage depending on your bike weight.