I (Tyler Folsom) built two prototype soft suitcases. My wife (Fran Solomon) and I toured with them in Holland in June 2002. The as-built version differs from the initial design. I had initially planned on a telescoping aluminum frame, but instead used PVC tubing. This plastic is light weight, strong, and easy to work with. To go from expanded mode (for packing the bike) to small mode (for carrying the case on the bike), I just need to remove four tubes. The outer dimensions of the case are 28.5 x 21.5 x 10 inches (expanded mode) or 17 x 21.5 x 10 (small mode). The small mode is more than adequate to carry a duffel bag with your gear.
I made a pattern and had the fabric sewn by Commercial Fabric Mfg. Co, 2224 - First Ave. S, Seattle 98134, 206-682-1082. They charged $125 each and needed 3 to 4 weeks lead time.
The luggage rack is an integral part of the design. It stays attached to the bike when packed and straps to the suitcase frame so that the bike cannot move relative to the frame. The rack is built of steel on the lower part and aluminum angle brackets on the upper part. The rack is 10.25 inches wide. Fran's is 12" long; Tyler's is 11.25". Mine needs to be shorter so that my heels don't hit it. Both racks extend to about the back of the rear tire. The aluminum angle brackets form a U shape to hold the suitcase in position. D-rings on the fabric accommodate straps that attach the suitcase to the rack and bike. When the bike is folded, these straps attach the bike to the suitcase frame. The suitcase can be carried upright (Tyler's preference: 21.5" high and 17"long) or lower (Fran and people of normal height: 17" high and 21.5" long).
Suggestions for changes:
The suitcase closes in expanded mode with Velcro and three straps. These straps have two sided plastic release buckles. These should be replaced by something that stays more solidly shut, such as a belt buckle. Airline baggage handlers tend to grab the bag by the straps, which are not designed to be handles.
The handle is a piece of nylon webbing that girdles the bag. It needs to be more obvious (maybe a different color) and it needs to be more comfortable. It needs additional padding.
Fran's bag experienced heavy wear at the points where it contacts the rear sides of the luggage rack. The fabric should be reinforced here.
Have made additional trips with the cases to China and California. The PVC for one case got slightly damaged on the way to China and moderately damaged on the way back. No damage to the bikes. I needed to replace some PVC parts after return from China. The bags tend to get a hole where the wheel hub rubs against it. Put some padding on your hub.
Our trip to North California was a camping trip. We did not try packing the gear before taking off and it was more than expected. I wound up carrying my suitcase on the bike in expanded mode. It is possible, but we will use front panniers for our next camping trip. We went there by car, and after the bike trip brought the bikes on buses and a rental car back to our car.
Last updated: Oct 7, 2008