Donga wrote:
>
> I made one for about $100 and it's beaut. It's side-opening, which is
> much easier to load than the cardboard boxes you can get from a LBS for
> free. I got the idea from Excelsports, which used to sell them.
>
> I got a large sheet of Corflute from a signwriting supplier. I cut it
> into two pieces, then folded it to make two 'boxes' with three sides
> each. One half is slightly larger than the other, so it slides over its
> mate. Vacuum tends to hold them together.
>
> In the folded corners, I left tabs and used Tarzans Grip to glue it up,
> then taped it to smooth off edges that might catch and tear. You could
> also rivet it. I got three sheets of foam to put on the sides and
> between the frame and wheels. The dimensions are around 1200x785x280 I
> think. You lay one side down, put in foam, put in the frame etc.
> another piece of foam, the wheels, another piece of foam and then the
> other side slides over. Lastly I lash it with some straps - as much for
> carrying as holding it together.
>
> It's cheap, light, strong, fairly durable. Saved about $400+ over a
> store-bought version. I've used it for a dozen flights and it's hardly
> worse for wear.
>
> If you want to email me for some pics, add 'ike' before @.
>
> Donga
I use a Qantas bike box. It cost me about $15. I take off the front
wheels and use a little fork protector cap that came with the bike. On
my tri bike, I loosen the handlbars and rotate them down, so I don't
need to take the profile bars off. I take the seat off my tri bike
because it's got bidon cages behind it that don't fit. I leave the
pedals on and just tuck a towel around them so they don't poke through.
It's incredibly quick and I've had no problems.
Tam