Traveling to and from Europe can be a daunting task that cost a lot of extra money and headache. I hope I can help in this task. I travel to Europe almost every year and never pay extra if it can be avoided.

Baggage: Note Air France is charging for extra size bike box.
Most airlines have very similar policies. one checked bag and one carry on. the checked bag can on exceed 50 lbs and can not be over 90cm x 75cm x 43cm (35.5in x 29.5in x 16in). Everything over is considered oversize. British Air will wave the fees for oversize to a point but will not wave the fees for over weight. A bike case less than 50 lbs would be free if it was the only checked bag.

The Checked bag: The trick is to not exceed the weight limit. Here is how to do that, do not use a bike bag that you would normally buy in a bike store or online purchase they simply weight to much. Most bike boxes weight from 14 to 20 pounds, way to much. Here are a number of pictures of the box I built.

I built this out of corrugated plastic I bought at Tap Plastic the pop rivets and straps at home depot. you must make sure that the straps are attached to the boxes pr Customs will lose them and you will find you box coming out simply taped together, Customs will open your box coming and going every time I promise you. what size to make the box , easy simply keep the over size less than the multiplied dimensions given above 90cm x 75cm x 43cm (35.5in x 29.5in x 16in) or 16756 square inches. I made this box 10″ x 29″ x 46″ or 13340 square inches well under the carry on limit,  simply make the inside box 3/4 of an inch smaller in with and length.You can go to a bike shop and get a bike box but the dimensions will be wrong and cardboard is to heavy. There is one company that does make a plastic box like the one I described www.crateworks.com but they over build it and push the weight to 22 lbs.
The carry on: I find a number of requirements for the carry on. Easy to get in and out of, the largest size possible and shoulder straps to carry on the back as need be. Roll around are great except when you are also fighting a bike box. Here is what I have found to fit my needs.

It is a Osprey Transporter 60.  The 47 is the exact size the airlines allow but the 60 is slightly larger you just don’t pack it to its limit. You can find it at Amazon. This bag is very durable and has great shoulder straps that tuck away when not needed.extra Carry on.  I know that them seems strange but I recommend to the guys to carry a man purse. I carry a across the back pack, I carry my laptop, small bottles of Vodka, head phones and UPS batteries and cables.
Note. you can no longer place UPS batteries in check baggage, they must be in carry on.

This version is no longer available. I just picked this up for Cindy, the great thing about this one is it has rollers and backpack straps. The 45l is the only one that is carry on size