Tech Info
Tech Info

Below is some technical information that we've put together. We will add more resources as they become available. If there's a specific question you have, please email us at

(Instructions in PDF format)
  1. Before disassembling your bicycle, become familiar with your bicycle’s specific torque specifications to prevent accidental over tightening of any parts upon reassembly.  Blue Competition Cycles and Aerus Composites torque specifications can be found here  Parts damaged and/or destroyed as a result of over tightening are not covered under warranty.
  2. Remove pedals using a pedal tool or Allen wrench.  
  3. Remove handlebars from stem. To remove handlebars from stem, use Allen wrench to remove stem faceplate bolts. Once the faceplate has been removed, the bars will come loose and will hang by the shifter and brake cables. Re-secure the faceplate bolts to the stem to prevent accidental misplacement.
  4. Remove seat post with saddle still attached. Use an Allen wrench to loosen the seat clamp bolt(s), and slide the seat post out of the frame with the saddle still attached. Once the post and saddle have been removed, re-secure the seat clamp bolt(s). Place the seat post and saddle into the small inside pocket of the travel case.  
  5. Remove wheels. Once wheels are removed from bike, remove skewers from wheels and place into the small inside pocket of the travel case. Skewers are more likely to scratch other items in the bag if left on the wheels. Wheels should be placed into the large wheel pocket of the bag. Snap the wheel compartment shut after wheels are in place. 
  6. Remove rear derailleur using Allen wrench. Place rear derailleur into the small, grey rear derailleur bag that is included with the bike travel case. Secure the small grey bag to the inside of the rear triangle on your bicycle frame using the attached straps. 
  7. Attach blue padded top tube protector to the top tube of the frame. Secure handlebars to the frame using the straps attached to the blue pad.
  8. Your bicycle should now fit comfortably into the Aerus bike travel case. Use the strap on the bottom of the case to secure the bottom bracket and hold the bike into position. Ensure that you have not left any items aside. Check for small bolts, stem faceplate, seat clamp bolts, seat clamp, seat post, saddle, skewers, and anything else that may have been set aside in the disassembly process, and ensure that all items are placed into the bag. Close the bag using the large outside zipper. 

Internal dimensions for the case are 105cm x 65cm x 18cm. External dimensions depend entirely upon the size of the bike enclosed. Empty weight is 9.8 pounds.


“I love my Aerus travel case!  I like to go to Home Depot or Lowes and buy two of the 6 foot long foam tubes used for 1-inch hot water pipes, cut them to match the length of each tube, fork blade, seat stay, and chain stay, and zip tie them into place for extra protection.”
–Tina Pic  (Five-time National Criterium Champion) 

“I shift the chain into the big ring so that the chain covers the teeth.  I use zip ties to hold the chain into place on the big chain ring so it does not slip off during shipping.”
–Brent McMahon (Canadian National Champion, New Orleans 70.3 Champion, Two-time Xterra World Championships 3rd Place)

“I sometimes turn the bike around in the case so that the chain rings are actually not resting in the slit in the foam block at the bottom of the case. This adds extra cushion.”
–Seth Wealing (3rd Place Finish at Xterra World Championships, US National Xterra Champion)

“I like to keep my packed bag lightweight so that I do not have to pay overweight luggage fees at the airport. I accomplish this by not packing any extra gear into the bag with the bike. I always carry my shoes and helmet separately in a carry-on bag.”
–Andreas Raelert (Two-time Olympian, IM Arizona Champion, 2nd place 70.3 World Championships)

“The Aerus travel case is great because it is spacious enough to hold a large amount of equipment, but small enough that it can avoid oversized luggage fees.  If I am traveling with two bicycles, I can remove the wheels and pack both bicycles into one Aerus bag and carry the wheels separately in my Aerus Biospeed wheel bags.”
–Laura Van Gilder (US National Cyclocross team member)

“I find it useful to carry a small bottle of degreaser, a wiping rag, a set of Allen keys, and a package of 50 zip ties with me when I travel with my bike.”
–Sarah Haskins (US National Triathlon Champion, Member of 2008 US Olympic Triathlon Team)

“To avoid questions about what is inside the bag, I try to look as inconspicuous as possible. Fortunately, the Aerus bag is discrete looking. If I walk into the airport with a ‘Bound for Paris Roubaix’ shirt, a helmet strapped to my bike bag, and shoes sticking out of my backpack, I’m a lot more likely to be charged an oversized luggage fee.”
–Heather Wurtele (IM Cour d’Alene Champion, 3rd place IM Canada)

“I am a tall guy and ride one of the largest bikes Blue makes. When packing my Triad, I remove the front brake caliper from the fork, remove the fork, and put the fork into one of the inside pockets.  This allows me to tilt the bike forward so that the seat mast does not stick up too high. I have no trouble fitting my bike into the Aerus bag, and imagine that a bike of any size will fit into the bag, whether it is a road, mountain, cross, or time trial bike.”
–Trevor Wurtele (Top 15 IM Arizona)

For Blue Competition Cycles Product Information and Support Call (800) 470-2606