Packing a 20" Wheeled Dahon Folder for Commercial Air Travel
With airlines strapped for cash, charging for oversized baggage is now the norm rather than the exception. To avoid any surprises at the check in counters, we use only cases that conform to airline regulations. With a 62" case limit (length + width + height), the only bikes that would fit are folding bikes with 20" or smaller wheels. Folding or travel bikes with 26" or 700cc wheels by default will not fit due to the bigger diameter wheels.

We've outlined the basic steps below on packing your bike for commercial air travel. We use standard 30" or 29" suitcases with dimensions that hold the bike well.
Standard 30" MiniJumbo suitcase holding Dahon Speed P8. Note the layers of duct tape and extra cross strap to keep the case intact from the rough baggage handlers.
1) Remove wheels, pedals, seatposts, racks and sliding stem of the folding stem. On the newer 20" wheeled Dahons, you can now swing the fork in between the rear chainstays (see picture on right). This is a new feature on 2005 and later frames making your folded frame a narrower package. Shifting the rear derailleur to the inside will help make the width narrower.

Lay your frame in to your case as shown below. Note position of handlebar and seatpost.
2) With the quick releases off your wheel, lay the back wheel on the left side of the case (cassette side facing down)
Then lay your front wheel on the right side of the case. Make sure that the axle of the back wheel goes in between the spokes of the front wheel.

And your done ! About a 5 minute operation with practice.
Tips: Please practice packing your bike weeks before your trip. Once you've successfully packed it, take pictures of how you did it and tape a printout inside your case. We suggest using a bungee cord to tie everything inside the case to make sure nothing falls out when airport security opens it. Also mark your case as to which side points up when opening case.

Duct tape all the corners of your cases and use cross straps to extend the life of your case. Baggage handlers are brutal. If using a rack, try using a rack with foldable legs as it makes packing easier.

Below is another variation of packing the Helios P8 bike inside the very common 29"Samsonite Oyster. A standard Arclite rack is packed with the bike. It's an exact fit, so taking pictures of how it is done will help you repeat the process.