Today’s guest post comes from James Sowerwine, an avid traveler and bikepacker who takes his Montague Navigator folding bike and custom bikepacking setup with him everywhere he goes. He has a unique way of packing his bike and gear for airline travel and has kindly agreed to share it with us and the Montague community.<\/p>\n
NOTE: The following packing instructions involve more disassembly than the standard folding procedure for a Montague bike. Only attempt if you are confident in your mechanical abilities. If you do attempt this process, take note of the order of all parts to make reassembly possible. If you have any questions about your bike, please bring it to a professional bike mechanic.<\/strong><\/p>[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” header_2_font=”|600|||||||” global_colors_info=”{}”] A stock Montague Navigator bicycle can be used as a reliable touring bike that fits into a 62 linear inch (LxWxH) suitcase with a few modifications. This allows bike and rider to fly for the base cost of a plane ticket as most airlines include a single checked bag up to 50 pounds (23 kg) and 62 inches (158 cm) free of charge. How to do this with a stock model:<\/p>\n 1.<\/strong> Add quick disconnects to both shifter cables and the rear brake cable. I used Ritchey brand Bab cable disconnectors (https:\/\/ritcheylogic.com\/bike\/accessories\/bab-cables-disconnectors). This allows all three cables to be temporarily split at a point on the top tube when packing the bike for travel. Cable tension is restored when the disconnects are recoupled, generally without need for re-tuning of shifters or brakes. Note that you will need a second set of brake and shifter cables to install the disconnects. I have also added colored-coded electrical tape to the cables to enable faster reassembly as it is easy to confuse which ends go together. If you do the installation work yourself your total cost for adding the disconnects will be around $50,<\/p>[\/et_pb_text][et_pb_image src=”https:\/\/www.montaguebikes.com\/wp-content\/uploads\/2022\/10\/Cable-Disconnects.jpg” title_text=”Cable Disconnects” _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”] 2.<\/strong> Purchase a<\/span>n <\/span>extra-large<\/span> <\/span>nylon <\/span>pizza delivery bag<\/span><\/span> <\/span><\/span>that is at least 28 inches square by <\/span>four<\/span> or more<\/span> inches <\/span>high<\/span>.\u00a0 The bags I purchased several years ago do not appear to be available but see the \u201cBig Daddy Pizza Jacket\u201d on deliverybags.com for a similar product.\u00a0 Most of these larger pizza delivery bags have a set of <\/span>hand-held<\/span> <\/span>carrying straps that double as over-the-shoulder straps if the bag is used as a backpack.\u00a0 Look for bags that are advertised to fit <\/span>at least <\/span>two 28\u201d pizza boxes as two 700c wheels<\/span> and a frame<\/span> are roughly the same <\/span>size <\/span>and shape<\/span>.<\/span>\u00a0 Note that you may need to reinforce the stitching where the straps are sewn onto the bag with upholstery thread<\/span>, and it may be helpful to remove the padding from the bag to reduce the bag\u2019s volume if you choose to rol<\/span>l<\/span> <\/span>the bag<\/span> up and store on your bike when touring<\/span>.<\/span>\u00a0 Your total cost <\/span>may<\/span> vary here but <\/span>will <\/span>likely <\/span>be around $65.<\/span><\/span><\/p>[\/et_pb_text][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”] 3.<\/strong> You are now ready to pack the bike. To fit the bike into the bag (in no particular order):\u00a0<\/span><\/span><\/p>[\/et_pb_text][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”] a.<\/strong> Remove the pedals, seat post, front wheel and any bottle cages.\u00a0<\/p>\n b.<\/strong> Un<\/span>couple<\/span> the cable <\/span>disconnects<\/span>.\u00a0 Then separate the front portion of the <\/span>frame<\/span> from the back by releasing the quick release<\/span> lever<\/span> that allows the Navigator to fold and then <\/span>loosen<\/span> the two bolts on the clamps on the <\/span>seat<\/span> tube that are located above the quick release.\u00a0 The front frame assembly can then be <\/span>slid\/<\/span>lifted off the back<\/span> assembly<\/span>.\u00a0 A bit of gre<\/span>a<\/span>se on the <\/span>seat<\/span> tube helps here.<\/span><\/span>\u00a0<\/span><\/p>\n c.<\/strong> Remove the <\/span>stem<\/span> from the fork<\/span> so that <\/span>the bars<\/span> can be turned fully sideways for packing<\/span>.\u00a0 Remove the disc brak<\/span>e<\/span> rotors to guard against <\/span>bending<\/span> in transit, the brake mechanisms, and the rear <\/span>derailleur so that they can be <\/span>placed<\/span> safely <\/span>around other parts<\/span>.<\/span>\u00a0 Do not disconnect the cables <\/span>from the<\/span> brakes or rear dera<\/span>i<\/span>lleur<\/span> assemblies<\/span>.<\/span><\/span>\u00a0<\/span><\/span><\/p>\n d.<\/strong> Stack the front frame assembly and handlebar on top of the rear wheel. Then complete the sandwich by placing the front wheel on top of the front frame assembly. The center point of the two wheels should be slightly offset from each other.<\/span><\/span><\/p>\n e.<\/strong> Compress the wheels together using four straps placed at 90 degree intervals. I use 40\u201d Sea to Summit hook release accessory straps because they are light weight, durable and have a simple design.<\/span><\/span><\/p>\n f.<\/strong> Secure<\/span> remaining parts <\/span>inside<\/span> the <\/span>wheel <\/span>sandwich<\/span> with zip ties<\/span>.\u00a0 I <\/span>use<\/span> ties that have an additional plastic tab <\/span>on the <\/span>tie <\/span>mechanism <\/span>that allow<\/span>s<\/span> <\/span>the tie<\/span> to be released and reused<\/span> when repacking for my flight home<\/span>.<\/span><\/span><\/p>\n g.<\/strong> Protect vulnerable points that may stick out of the sandwich <\/span>including <\/span>the <\/span>stem riser, rear wheel quick release,<\/span> and<\/span> top of the seat tube by zip tying on <\/span>small <\/span>single-use <\/span>plastic cups or other similar plastic clamshell type containers.\u00a0 Bikepacking bags stuffed with lightweight clothing can be added to further support the frame and wheels.\u00a0 Clean salad containers also work well to provide support in empty spaces in the bag.<\/span>\u00a0 Note that the biggest risk of damage comes from exposed parts of the frame being dragged along floors by baggage handlers \u2013 these are the points I protect with a plastic cup or salad container<\/span> lid.<\/span><\/span><\/span><\/p>\n h.<\/strong> Place a brace where the wheel would sit in the <\/span>front <\/span>for<\/span>k<\/span>.\u00a0 Your local bike shop should have <\/span>lightweight <\/span>friction-fit <\/span>plastic braces <\/span>available as they ship out with new bikes and are generally thrown away after initial <\/span>bike <\/span>assembly.<\/span>\u00a0 Such braces can be reused indefinitely even though they are intended <\/span>for <\/span>single use.<\/span><\/span>\u00a0<\/span><\/span><\/span><\/p>\n i.<\/strong> Slide the dissembled bike into the pizza bag. I close the bag with a set of D ring belts that allow security staff to open the bag and inspect the contents.\u00a0<\/span><\/span><\/span><\/p>[\/et_pb_text][et_pb_image src=”https:\/\/www.montaguebikes.com\/wp-content\/uploads\/2022\/10\/Ready-for-Bag2.jpg” title_text=”Ready-for-Bag2″ _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][et_pb_image src=”https:\/\/www.montaguebikes.com\/wp-content\/uploads\/2022\/10\/Packed-edit.jpg” title_text=”Packed-edit” _builder_version=”4.14.4″ _module_preset=”default” hover_enabled=”0″ global_colors_info=”{}” sticky_enabled=”0″][\/et_pb_image][et_pb_image src=”https:\/\/www.montaguebikes.com\/wp-content\/uploads\/2022\/10\/In-Bag-v2.jpg” title_text=”In-Bag-v2″ _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][\/et_pb_image][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”] 4.<\/strong> You are ready to fly. The bike will need to be delivered to TSA\u2019s oversized bag check counter due to its width but will not be charged oversized luggage fees by the airline. Note also that the size of the bike in the bag matters to the airline rather than the bag itself, so the bag can be a bit larger than 62\u201d LxWxH as long as the packed dimensions are at or even slightly over the size limit.<\/p>\n 5.<\/strong> Finally, note that disassembly and reassembly both take around two hours, and that the bike frame is susceptible to cosmetic damage in transit when packed as described above. I only fly a bike this way when traveling on international flights.\u00a0<\/p>[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row _builder_version=”4.14.4″ _module_preset=”default” custom_margin=”3px|auto||auto||” custom_padding=”19px||||false|false” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” header_3_font=”|600|||||||” global_colors_info=”{}”] Additional modifications to my Navigator and associated travel kit to facilitate touring:\u00a0<\/strong><\/p>\n Weight: <\/strong>The bike, bikepacking bags, sleeping kit, repair kit, lock and travel bag weigh around 40 pounds (18 kg) when checked.\u00a0 I generally use the seat post bag as a carry on.\u00a0 It weighs around 7 pounds, though this is more reflective of my choices for clothing and toiletries and could be reduced.\u00a0 Most of my clothing is smartwool or similar fabric.<\/span>\u00a0<\/span><\/p>\n Cost: <\/strong>I paid about $950 for a stock Navigator.\u00a0 Upgrades (cable disconnects, handlebars, headset, dynamo system, wheels and tires, front cog set, saddle, pedals) have cost around $2500 with labor (Many thanks here to Nicholas Carmen and the rest of the folks at The Bicycle Shop in Anchorage, Alaska).\u00a0 Bags were around $600, for a total cost of around $5000.\u00a0 The sleeping kit cost an additional $1000.\u00a0 While the project fails a straight dollar to dollar economic analysis (around $2000 in luggage fees saved to date vs. $5000 for the bike), the ease of knowing I can show up with a single bag and fly without question, and the ability to carry the bike in a backpack justifies the extra cost for me.\u00a0 I also find the bike to be incredibly comfortable to ride, with no back pain issues to date.\u00a0 It\u2019s a specialty concept, but for those folks who are interested to take the time to follow a similar path, and who are willing to risk a bit of cosmetic frame damage while in transit, it\u2019s a lovely way to ensure that your bike is with you wherever you go.<\/span>\u00a0<\/span><\/p>\n Overall<\/strong>:<\/strong> Monatgue\u2019s Navigator frame fits the role of travel touring bike well for several reasons.\u00a0 It\u2019s remarkably comfortable, as the riding position is nearly vertical and the cockpit space is extremely slack.\u00a0 It comes with a rear rack for any trips that require the rider carries several days meals.\u00a0 The frame is light enough that it remains practical to carry the bike in a backpack, yet is durable enough that it survives traveling in checked luggage in a lightweight bag.\u00a0 The bike can be used on dirt and gravel trail surfaces.\u00a0 Its best attribute is that it goes with me as a standard checked suitcase, which means I don\u2019t have to worry about excess baggage costs, and perhaps more to the point, it transfers easily when I fly a codeshare itinerary with both major and regional air carriers that might otherwise reject a larger box.\u00a0 It also folds as originally intended by Montague, so I don\u2019t have trouble securing a spot when taking a bus, train, subway or pedestrian ferry that might otherwise reject a bicycle.\u00a0 It is an unusual but wonderfully well fit tool for seeing the world at eight miles an hour.<\/span>\u00a0<\/span><\/p>\n I am happy to answer how-to questions.\u00a0 Please contact me at james.sowerwine [at] gmail.com<\/strong><\/span><\/p>[\/et_pb_text][\/et_pb_column][\/et_pb_row][\/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.14.4″ _module_preset=”default” custom_padding=”0px||0px|||” global_colors_info=”{}”][et_pb_row _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_column type=”4_4″ _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” header_2_font=”|600|||||||” global_colors_info=”{}”] <\/span><\/span><\/p>[\/et_pb_text][et_pb_image src=”https:\/\/www.montaguebikes.com\/wp-content\/uploads\/2022\/10\/Entire-Bike-EDIT.jpg” _builder_version=”4.14.4″ _module_preset=”default” title_text=”Entire-Bike-EDIT” hover_enabled=”0″ sticky_enabled=”0″][\/et_pb_image][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” global_colors_info=”{}”] I have been eager to write up how-to notes for flying a Navigator for several years now, but have been equally uneasy about writing about the solo international touring that I use the Navigator for.\u00a0 My hesitancy comes from a desire to be humble in my online communication the Instagram and Twitter age, as there are many people in the world who have traveled more or ridden both farther and faster than I ever hope to, and uncertainty about how best to tell my own motivation for visiting other places.\u00a0 However, it\u2019s impractical to describe how to build a specialty bike without explaining at least a little about <\/span>why<\/span><\/i> you built a specialty bike; the two topics are inextricably linked.\u00a0 I very much want to share my own personal why as well as the how in the hope that others will think to themselves \u2018Oh, I have wanted to do that and know I think I can do that\u2019 and possibly \u2018Oh, I had never thought about that but know I think I want to do that\u201d.\u00a0 An explanation of my motivation for this project follows, as well as a few observations about trip planning.<\/span>\u00a0<\/span><\/p>\nPart 1: How to fit a Montague Navigator in a single standard suitcase<\/h2>[\/et_pb_text][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” header_2_font=”|600|||||||” global_colors_info=”{}”]
About the Bike<\/h3>[\/et_pb_text][et_pb_image src=”https:\/\/www.montaguebikes.com\/wp-content\/uploads\/2022\/10\/Entire-Bike-on-Ferry-EDIT2.jpg” title_text=”Entire-Bike-on-Ferry-EDIT2″ _builder_version=”4.14.4″ _module_preset=”default” hover_enabled=”0″ global_colors_info=”{}” sticky_enabled=”0″][\/et_pb_image][et_pb_text _builder_version=”4.14.4″ _module_preset=”default” hover_enabled=”0″ global_colors_info=”{}” sticky_enabled=”0″ custom_margin=”||0px||false|false” custom_padding=”||0px||false|false”]
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Part 2: <\/span>But w<\/span>hy fit a Montague Navigator into a suitcase? (It\u2019s not for everyone <\/span>but may be for you)<\/span><\/span><\/h2>\n