Bike boxes on Easyjet

cardboard box is fine

I've seen plenty of folk use a cardboard bike box as you describe to fly with easyjet, the only problem you may have is if the box gets wet while sat outside before it's loaded on to the plane or sometimes airlines ask to check what's inside or have you let your tyres down, maybe pop a roll of tape at the top.

You should be fine

"...as I looked through the back window of the van on the way to the airport...my cardboard box in the trailer was melting in the rain on the way to Geneva airport from Chamonix..... "

I've used an old box from the bike shop on EasyJet several times with no problem.

The EasyJet website says only the bike should be in the box, not other luggage, and the tyres must be deflated. I never follow either rule.

Where are you based?

Friend of mine in Perth was looking to hire his out, but never really got any response to ads and gave up. He still has a couple of bags, if that's any use?

Cardboard box is fine, when are you going? Where are you? There may be someone local with one to borrow for beer tokens?

I've used a cardboard box before. Covered it (well, two of them actually, his and hers) in parcel tape to make them a bit stronger, more weatherproof and easier to spot at the airport.

Loads of places rent out bags, whereabouts are you? I'd rather be hiring a bag/hard case than risking putting my pride and joy in a cardboard box with airport baggage handlers...

Cardboard box is ok but cut it down as much as possible.

You can't get the thing through the doors or around the barriers at Geneva if using a trolley like I was with my battery less ebike without it being stood up.

Then you can't see where you are going 🤔.

Also cut extra handle slots in the ends as this makes it a lot easier to drag about.

Take extra tape for the journey home 👍

Cardboard box is fine.

They were checking bike box size at Edinburgh airport this year so check yours before you go.

Thanks everyone for the replies, at least I know the cardboard box is a viable option, even if it has its pitfalls.  I'm based top end of North Yorks, closest I can find to hire is Edinburgh bicycle co-op in Newcastle but I could do without having to make two trips up there to collect/return, but it might be worth it if I can tie it in with doing something else up there.  Rain is a worry with cardboard though it's only the bit across the runway that should present a risk - no trailers involved in the transfer - and that can hopefully be managed with parcel tape!

Have had a cardboard bike box work a couple of times. Then on the second trip it rained.  That was very bad thing. It simply fell apart.  Ended up getting a proper bag next day’d out to ciclo in Spain.

The other issue I had with a cardboard box was size. The regular big luggage scanner at Malaga wouldn’t take it. So I had to get escorted into the basement to one of the cargo scanners, which was stressfully delaying.

The other issue I had with a cardboard box was size. The regular big luggage scanner at Malaga wouldn’t take it. So I had to get escorted into the basement to one of the cargo scanners, which was stressfully delaying.

My mate had the same issue at Malaga with a bike box alan clone. I may be wrong, but I don't think it was an issue the second time we were there (2019-ish).

I wrapped a cardboard bike box in industrial clingfilm, put ratchet straps round to help handling.  No issues at all, assembled and rode from train station.

We had to weatherproof 2 boxes for a race event used 3 spray glues and some 1000 g polythene from screwfix to completely cover them  worked out ok  but did get a bit soggy in steady rain, will you have somewhere dry to store the boxes when away? Mrs G had to unpack her bike on 2 overseas trip to get sniffed for drugs! ( clear!) factor that in too?

@OP, When are you going?

Eldest has done box or bag a few times with Easy Jet to Geneva.

Geneva airport has a bike building area with an area to recycle bike boxes - either a fellow traveller can use to fly out, or they recycle.

Something I forgot to add is my mates hired a couple of fibreglass type bike cases with a steel rod in the middle to transport there downhill bikes

They really struggled getting them through check in because of the 32kg limit due to the cases weighing so much.

A lad in the queue had a proper padded bike bag and they made him go to the far end of check in at Manchester to the oversized luggage conveyor.

I found a specialized box that fitted perfectly inside my old bike bag, best of both worlds. Sadly all my bikes have outgrown it now!

Next time I reckon I'll just go with the cardboard box + mile of tape approach to weatherproof it. And those big bubble packaging things, not bubble wraps, the ones that are more the size of sandwich bags, perfect. Remember to make some handles. But not wheels, it'll slide along the ground better than most bags will roll

I hadn't noticed that easyjet have dropped their size limit for bikes, so that's something.

@OP, When are you going?

The reason I ask is if we've got a bit of gap between our trips you can borrow my Merlin one, for free.  I'm only in Leeds so it's not unachievable to get it to you.

I'm taking 4 (!) enduro bikes by plane shortly and decided to go with cardboard. Done right it's actually a good material for protecting bikes, think crumple zones. I'm not expecting them to last but they only have to do a couple of flights.

I had some custom double wall boxes manufactured that were big enough for our bikes and small enough to go in our cars and through the oversize scanner. You could just go to Halfords and ask they are always happy to give out boxes but I had a particular shape and number in mind.

I glued another layer inside so they are now quad wall cardboard, pretty strong. I used spray contact adhesive it's also perfect for carboard crafting inserts.

To protect from rain I covered the box in pallet wrap with a little bit of spray adhesive to hold in place then taped at the edges.

Then I added 3d printed handles to the box in yellow so they can't be missed by baggage handlers.

The finished article, the top will be taped down and opened with a knife. I'll probably put spare tape in each box in case they are opened;

I created inserts that suspend the frame and hold parts in place;

Test fit;

I'll also be protecting the parts with bubble wrap / foam, then more inserts on top to hold everything in place, then filling box with void fill air cushions (very light) because I can.

The main limit is the 32kg overall weight as this is the max baggage handlers are supposed to lift. These boxes are actually lighter than a hard case at under 6kg with inserts.

I have a normal hard case but it's are not it's own issues; It is heavy and not right shape for full suss, it's ok for a hardtail.

Ok I could probably buy one that is the right size / shape, but I don't want to pay for one never mind four!

@OP, When are you going?

15th to 22nd July. I don't think the Merlin one's big enough unfortunately, internal length is 125cm and my bike is 126cm wheelbase so won't fit. Though if you think differently I'd take you up on your generous offer!

Yeh we've got storage space while we're away, and parking/transfers are dropping us very close to the terminal so exposure to weather should be minimal hopefully.

Flying with either bag or box seems to be a hassle - I wish we were just driving like we have in the past!

Get yourself some pallet wrap & take it for the trip back.

A mate had his road bike in a cardboard box when we flew out to Girona.

Boarding at Manchester, it was lashing down, absolutely torrential rain.

On the baggage carousel at Girona was a pile of soggy cardboard with various bits of expensive bike hanging out of it...

Cardboard is fine but use lots of packing tape and put a roll inside the box for the return journey!

easyJet are fine with bikes, they're very used to it. You can safely ignore the "guidance" about only packing the bike - we've always packed clothes, tools, spares etc in the bike box and me er once had any issues.

15th to 22nd July. I don’t think the Merlin one’s big enough unfortunately, internal length is 125cm and my bike is 126cm wheelbase so won’t fit. Though if you think differently I’d take you up on your generous offer!

This is a good point well made and as I never accounted for the change in size of my own bike (now 128cm) when I got it, after doing a test fit and mine doesn't fit either! My buddy has just snapped my hand off for that one as he's a midget so that's all good.

So, I have just purchased a EVOC Pro which is max 130cm wheelbase to resolve my issue, I'm off 6-12 July, so you're more than welcome to borrow it for your trip as well.

@fooman if you've had those drawn up and got a cardboard company to cut/fold them to size, you could definitely make a few more and sell e'em on...

Fairly common in my cycling FB groups to post up and see if anyone has one they can loan out for a small fee.

I've got a couple of EVOC pros in the attic that seem to do a lot more flying than i do...

So, I have just purchased a EVOC Pro which is max 130cm wheelbase to resolve my issue, I’m off 6-12 July, so you’re more than welcome to borrow it for your trip as well.

@relapsed_mandalorian - I've just sent you a message about this, thanks.

for single crown bikes with long wheelbase you can always spin the forks 180 degress, removing about 8cm from the wheelbase due to inverting the offset.

@sing1etrack - Sutton Bank bikes hire our EVOC bags.

I'm using these guys (have a pickup centre in York) for a trip in a few weeks: bikebox-online.co.uk