Bikepacking Bicycle Build – St Thomas Bicycles

When flying Internationally with a bike, it is best to treat it as regular checked baggage to save massive airline fees. there is normally a maximum weight limit of 50 pounds per checked bag as well as a size restriction. The most common maximum size bag allowed is 62 linear (total) inches. A common size bag for checking through is: 27″ x 21″ x 14″.

Using these guidelines we build a fast bikepacking rig which is capable of quickly breaking down into a single lightweight boxed unit. The bike also provides for collecting power from pedaling into a backup battery for charging a cellular phone, laptop or Garmin when off the bike. This is accomplished with the use of a 6 volt front wheel dynohub by Shutter Precision coupled to a Busch & Muller E-Werk converter.

The foundation of this build is the excellent Serotta Legend titanium frame with a custom welded cro-moly steel fork by David Kirk. The frame has been fitted with stainless S&S couplers to facilitate in breaking it down into two smaller parts which can easily fit into a standard airline approved cardboard box. Shift and brake cables are also separated via Da Vinci cable connectors. The two frame pieces with removed wheels stack together nicely in a 8″ wide box x 28″x26″. This stays within the airline’s size restrictions. The bike can be reassembled within a few minutes using a small coupler wrench when the destination is reached.

FoxEYE F30 Headlight & Tailight for Dynohub

Brooks Cambium Saddle w/ Cut-Out Black c15

Mini MODS 60 tooth Chainring for Schlump

Da Vinci Cable Splitters for Brake & Shifter

TIGR Mini Titanium Bicycle Lock (Shown Open)

Build List
Serotta Legend 56 Titanium Frame $1500.00
Custom S&S Traveling Couplers 1200.00
Shutter Precision PV-8 Dynohub 130.00
Alex Adventurer 700c Wheel Rim 55.00
Wheelsmith Spokes Black Double Butted w/Brass Nipples (36) 72.00
Shimano Ultegra Rear Wheel FH-6800 300.00
Chris King 1″ Threadless Black Headset 275.00
Custom Cro-Moly Steel Fork by David Kirk 680.00
KRSEC CNC Titanium Colored Stem 50mm 27.00
Titanium Cable Housings 20.00
Salsa Cowchipper Wide Drop Flair Handlebars 50.00
Cane Creek Crosstop Interupter Brake Levers 33.00
Shimano Dura-Ace Caliper Brakes 100.00
Panaracer Gravelking Tires 700×26 (2) 75.00
Schwalbe Tubes 700×25-28 (2) 20.00
Da Vinci Cable Splitters for Brake & Shifter (2) 82.00
Titanium Seatpost 124.00
Serotta Titanium Seatpost Clamp 34.00
Schlump Mountain Drive Bottom Bracket 800.00
Mini MODS 60 tooth Chainring for Schlump 58.00
Tipsum Titanium Pedals 57.00
Advent 9 Speed Dropbar Shifters 130.00
Advent 9 Speed Cassette 11-46 44.00
Advent 9 Speed Long Cage Derailleur w/Clutch 59.00
KMC 9 Speed Chain 20.00
YAWYD (You Are What You Drink) Headset Cap 13.00
All City Handlebar Wrap 32.00
Brooks Cambium Saddle w/ Cut-Out Black c15 123.00
Tubus Fly Stainless Steel Rack 150.00
Twisted T Bag Rack (for front handlebar bag) 70.00
Zefal Frame Pump for 56 30.00
FoxEYE F30 Headlight & Tailight for Dynohub 25.00
E-Werk Power Converter for Dynohub 250.00
Anker 10000 Battery Bank 26.00
TIGR Mini Titanium Bicycle Lock & Hardware 125.00
Ortlieb Cockpit-Pack 65.00
Ortlieb Triangle Frame Pack 140.00
Ortlieb Large Seatpack 175.00
Ortlieb Handlebar Pack 160.00
Ortlieb Front Fork Bags (2) 143.00

Total Cost of Serotta Bikepacking Travel Bike $7,472.00

Total Weight Fully Loaded with Gear Minus Food & Water 40.2 Pounds.

Weight Without Bags & Gear 29 Pounds.

Camping gear includes Neoair Uberlite sleeping pad, down sleeping bag, tent, titanium cooking pot, cup & alcohol stove, merino wool clothing, rain gear, basic tools, spare tubes and head torch. Food and hydration pack is carried in an Ortlieb Atrack BP backpack shown below.

Leave a Reply Cancel reply