Packing S&S tandem for airplane travel

[bdweiss]

In the past we had a Santana S&S tandem that went into Santana’s hard sided case that had the layered foam with all its cutouts.
But,  now we are traveling with an S&S-coupled Co-Motion that does not come with such a case.  Instead, we cover all the parts with cordura padding and zip tie everything together so the parts don’t shuffle around in the cases. That works fine, but it takes SO long to pack up the tandem.
We’re wondering about buying some layers of polyethylene foam, making our own cutouts, and creating a packing arrangement similar to what we had for the Santana.
I’m writing to see if anyone has tried doing that.  If you have, I'd like to communicate with you about exactly what you did.

[Pat Lamb]

My S&S coupled single came with velcro'd cordura padding cut to fit all the tubes.  I've seen other custom builders (including, IIRC, Co-Motion) who sell that padding separately, though perhaps not cut and labeled.  That would be the first place I'd look.

Also S&S had a cargo net available for separate purchase that would hold all the bike parts together in their proper orientation in the case.  (They came out with that a year or two after I bought my bike.)  The selling point is that TSA can open the case and check everything out, then simply close the case back up.  It'd have been cheaper than replacing the shifter TSA cracked on my bike...

[bdweiss]

Pat - Thank you for responding.  I have that velcro'd cordura padding, and that's what we've been using.   But, what I'd like to do is create foam layers with cutouts for the parts, like we had on our old Santana case.   That eliminates the need for the padding and for zip tying parts together, which make packing way easier.  You can see it at the video from Santana at https://www.youtube.com/watch?v=p-pCAUWBaro

[freakson]

In the past we had a Santana S&S tandem that went into Santana’s hard sided case that had the layered foam with all its cutouts.
But,  now we are traveling with an S&S-coupled Co-Motion that does not come with such a case.  Instead, we cover all the parts with cordura padding and zip tie everything together so the parts don’t shuffle around in the cases. That works fine, but it takes SO long to pack up the tandem.
We’re wondering about buying some layers of polyethylene foam, making our own cutouts, and creating a packing arrangement similar to what we had for the Santana.
I’m writing to see if anyone has tried doing that.  If you have, I'd like to communicate with you about exactly what you did.
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If you're looking for specific guidance on creating a foam arrangement for your S&S-coupled Co-Motion tandem, it might be helpful to consult with bicycle touring forums, cycling clubs, or groups that specialize in travel with tandem bikes. Members of these communities may have experience creating custom packing solutions and can offer advice based on their own experiences. Remember to take your time and be thorough in your planning and execution to ensure that your tandem is well-protected during travel.