I'm flying with my DH bike next week so decided that I'd go for the free cardboard box from LBS option, however I've now got three boxes that are smaller than ideal. Should I:
1) just cram it in the largest box and wrap the result in gaffer tape,
2) create a box that's big enough (using the three boxes and lots of gaffer tape), or
3) something else (please don't suggest buying a bag / box as time is a little tight as is my budget).
Thanks.
4 Hope it doesn't rain when your box is sitting out in the open.
Get a bigger box.
Get a bigger box.
That was my first hope and why I've got three boxes - I've been to three LBS, where I got the biggest box from each, but as I live in a rubbish area for mountain biking the boxes are all from skinny XC or road bikes which seem to be a bit smaller than my DH bike. I was hoping to box my bike with the back wheel on but I think I'm just gonna have to bite the bullet and take both wheels off and use loads of padding.
Also, would I be better keeping the back wheel on, but removing the forks (single crown so no big deal and the rear mech has more protection), or keep the forks in and remove the back wheel, mech etc?
See also here
Having tried various bike boxes (back wheel and forks on, rear mech, bars and front wheel removed) I can say that they're pretty much fine apart from not fitting through the sliding doors at Geneva airport.
This Year I'm trying one of these TV Boxes which should take the frame and forks sandwiched between the wheels. It should be a bit less unwieldy. The box has arrived, it needs a coat of PVA waterproofing and I'll give it a try and see if the SX trail fits as expected...
Edit: If you don't want to buy a box I'm sure you might be able to find a TV box this sort of size?
Also, would I be better keeping the back wheel on, but removing the forks (single crown so no big deal and the rear mech has more protection), or keep the forks in and remove the back wheel, mech etc?
I'd take both wheels out, use an old axle or hub or something to brace the drop-outs, take the rotors off, they always get bent, remove the rear mech and tape it out of harm's way to a set or chain stay, the hanger too, leave the fork on, but remove the bars and tape them out of harm's way.
Pipe lagging on tubes, foam padding around frame, wheels etc. Old camping mats, or have a look for a local foam supplier.
Beware maximum weight stipulations, airlines seem to have got more and more anal about them over the last couple of years. You're probably right on the limit just with your bike if its a DH one.
Two boxes the same size taped together to look like one - don't bother trying to make a bigger one
Frame in one, wheels etc in the other side
Glue gun or similar them together, then plenty of wide, strong tape around the joins
I've taken two boxes on easyjet classing 1 as my "bike" (Frame and forks plus "padding") and 1 as my "case" (wheels, tools washbag, anything else not allowed in hand luggage) That worked pretty well, easier than carting a 31.9kg box in and out of the car etc. Of course it means booking on an extra bag and having your clothes in your hand luggage.
The unashamedly unhelpful bit: Bike bags make everything amazing. I know you're on a budget blah blah blah. But when you get round to buying a bag you'll wish you did ages ago. And make sure the bag has wheels.
Trying to be helpful: Take your wheels out, and take mech + hanger off the frame. If you're worried, take your disc rotors off. Stick something in between the brake pads so they don't jam on and cause trouble when you try to build the bike. Leave the bars on it they'll fit in the box, otherwise take them off and zip tie/velcro strap them to your forks/frame. That's about the extent of the requirements. If you're got a carbon Nomad or something, then you can damn well afford to buy an extra seat for it on the plane. For all other bikes, shove it in a box and stop worrying.
And don't forget the duck tape so you can seal the box up for the return journey 
Thanks for all advice. The bike is now boxed and ready for the flight tomorrow. The box is totally covered in tape for a bit of extra protection from rain and a bit of peace of mind! Now I just need to pack my clothes etc, get to the airport and enjoy a nice cold beer!
I'm not sure how people cope with the plastic boxes as I have a weight limit of 32KG and it weighs just over 30KG in a cardboard box (although I have snuck 2 pairs of shoes, my body armor and knee pads in - all for padding!).
I discovered on Saturday to my relief that the weight limit is actually 32.9kg, hit 33kg and you're in trouble.
Caution: Easyjet kilograms aren't the same as your kilograms at home, either that or the check in desks are all in patches of strong gravity
Bit late but it might be of use for others, the boxes Halfords use for their Apollos are pretty big and immensely strong, I had my Hemlock nicely packed in one (before I discovered I was about 6 kilos over the weight limit!).
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