paragliding training center
by Had Robinson
Read this entirely before beginning to pack your paramotor.
The steps below are for the Top 80, others may require some changes.
Make sure you do not exceed 70 lb. The Top 80, for example, has a shipping weight of about 55 lb.
WARNING: Shipping a paramotor as luggage on an airline is illegal unless it is brand new and has never been run. It is always better to ship things via FEDEX or UPS, but all traces of fuel must still be removed. If fuel vapors are present or detected, you could get in big trouble. If you want to ship your paramotor as luggage, you can remove the engine and fuel tank and ship them via UPS or FEDEX. Even with a new paramotor, you do not want have this recent adventure of a pilot who had his engine confiscated. The frame and other parts could then go as luggage on an airplane. Pack the engine and fuel tank in a heavy duty tote container in order to protect it. If you want to take your paramotor as luggage on a commercial airline, always get to the airport at least (2) hours ahead of time in case you problems. Most airports have a FEDEX or UPS facility close by so you can ship your paramotor if you have to.
a.) 19" x 19" x 40" heavy duty corrugated cardboard container. Bigger boxes may not be accepted by either the airlines
or commercial shippers as non-freight (UPS or FEDEX). The size specified here is the minimum that will work.
b.) About 2 sq. ft. of 1 1/2" thick hard foam packing material
c.) Soft foam to plug the spark plug hole and exhaust port
d.) HD plastic bags, bubble wrap, and packing tape
e.) Empty plastic water bottles with the caps on – they are a great packing material to fill up empty space in the box.
f.) Be sure to have BLUE threadlock on hand when reassembling the muffler attachment bolts.
1. Disassemble the paramotor – Remove: the harness and arms from the frame (leave the arms attached to the harness), the netting and all sticks/rods, the muffler, the airbox, the propeller (if it is a single piece, it will have to be shipped separately), the fuel tank cap and the cap with the fuel suction line, and the tank. Detach the fuel line from both the carburetor and the quick release fitting. Remove the spark plug.
2. Remove all traces of fuel from the system. To remove fuel from engine parts, compressed air is the best way to do it. A hair dryer also works for the fuel tank. Putting it in the hot sun for an afternoon will also do the job. "Baking" the carburetor in an oven at about 200 degrees overnight will also get every trace of fuel out of it.
3. Stuff small pieces of soft foam into the spark hole and the exhaust port to prevent foreign objects from accidently getting in like a nut or bolt.
4. Use the stiff foam to pad the paramotor. The weight of the paramotor is the engine. All packing must be carefully attached to the area around the engine, to the bottom of the frame, and the top of the engine. Re-attach the fuel tank (if it was removed) but not the fuel lines – be certain the fuel caps are not on the tank. The wrapped muffler fits nicely along the side of the motor per the photo. The airbox fits well just above the fuel tank. Wrap the harness in a HD plastic bag and slide it down the front all the way to the bottom. Watch out for the throttle cable. Place the wrapped netting hardware in a corner of the box diagonally. You must add packing material between the top of the motor and the top of the box. THE PARAMOTOR CANNOT MOVE WHEN IN THE BOX. A two piece propeller fits nicely in the box but not a single blade type which will have to be shipped separately.
Look at the following photos carefully for tips on how to place the stiff foam material. Be sure to LABEL the foam pieces for next time.
5. Be sure to put the labels on the side of the box that has the harness side. Do not put the labels on the top/bottom of the box. If you do it correctly, you will not have to drain the redrive oil, if you engine has a redrive. If, somehow, the box is stored prop side up or upside down – you may have a small mess. You might want to wrap the redrive with an old towel, just in case.
6. If shipping by FEDEX or UPS, be sure to insure it for full value. It is rare but these people can be rough on shipments (we just had a Top 80 destroyed by FEDEX ground). The most common damage is that your frame will get bent beyond repair. FEDEX/UPS 2nd Day Air is the best way to ship anything because packages are not handled by machines. However, it is expensive. Getting insurance with the airlines is sometimes impossible so check with your home/auto insurance company to see if they can insure your engine if you ship it via commercial airline.
Note: I am sorry to say that shipping anything these days has risk, so be prepared. Just be thankful you were not the hang glider pilots from Australia who traveled to Florida one year for a competition we were at. They had their brand new gliders bent in half by baggage handler idiots who used fork lifts and caught the gliders on columns when moving the gliders. I have seen airline baggage handlers throw luggage from the belly of a plane onto the tarmac – a distance of about 8'. No packing can prevent this sort of mishandling.