I haven't traveled with a regular frame but have traveled a lot with my 
folding Friday, both domestic and overseas.  Here are some general 
thoughts:  my hard case with everything but my helmet always comes in right 
at about 48-49 pounds.  Using folding or EZY pedals is highly recommended.  
Also, having lengths of cord and several washcloths to wrap around and tie 
onto the frame and around brake handles, etc, works well.  You can also get 
flexible plastic tubing in large diameter, split it and then cut it to 
length to protect chainstays, seatstays, etc.  

I've carefully honed the following list over the past 3-4 years.  It's not 
a camping list, but general all-purpose:

 Pump

Tires, 1-2 folders

Tire Gauge

Tire Irons

Tubes, 1-2

Patch kit

Allen 3-way, 4-5-6mm ball-end

Allen, 4mm ball end

Allen, 5mm ball end

Allen, 6mm ball end

(Allen tool comment:  it's actually nice to have all of them, especially if 
traveling with another person and bike)

Multi Folder

Leatherman or needle-nose pliers

Latex Gloves

Spare bolts, washers, and nuts

Handlebar Bag (Keven’s/Carradice Zipped Roll/Sackville Saddlesack xsmall)

Saddle Bag — Carradice Barley

Reflector Triangle

Seat Cover

Irish straps, 2 each, long

Irish straps, 2 each, short

Water Bottle + cage (I pack my lights inside the bottle)

Lights, Blinkies R/F 

Lights, Cygolights, USB cord (USB plug-in)

Gino light mount

Locks (I like the Abus Combination because I've gotten caught too many 
times with either me or Erin forgetting a key)

Chico Bag for storing frame-packing materials


-RCW

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