How to travel safely with foil boards and e-foil gear

Protecting fragile foil gear starts long before you zip a bag. Photograph every board, mast, front wing, stabiliser and e-foil component, list serial numbers and warranties, and build a detailed parts inventory. That documentation shortens claims, smooths customs checks and gives you a baseline if anything goes missing or arrives damaged.

Call the airline or transport provider early and get rules in writing. Boards and foil components usually count as sports equipment and carriers differ on fees and size limits. Battery rules vary widely; many airlines require removable battery packs and powerbanks to be carried in cabin and enforce Wh limits or forbid installed high-capacity batteries in checked baggage. Bring the battery spec label and follow manufacturer guidance well ahead of travel.

Pack to prevent impact and abrasion. Use a hard or hybrid board bag with ample padding and add bubble or foam between multiple boards. Protect nose and tail with foam blocks. Remove the mast and foils whenever possible and stow wings in a dedicated foil bag with blade pockets or foam separators. Bolt foam blocks to both sides of delicate wing tips and use a hard tube or padded sleeve for masts to avoid bending or crushing.

Carry a compact toolkit and spares. Bring allen keys, a torque wrench, marine grease, spare screws and bolts, a roll of protective tape and epoxy repair putty. Pack replacement fin bolts and small hardware that match your setup. Keep chargers, remotes and battery management components in your carry-on; powerbanks and spare small batteries should travel in cabin if allowed.

At the airport, arrive early and be prepared to gate-check oversized items. Gate agents are often more flexible than check-in counters when you explain you have sports equipment. Label every bag with contact details and consider FRAGILE tags for mast and foil bags. If you cross borders, carry proof of ownership and any temporary import documentation needed for expensive e-foil systems. Confirm your travel insurance covers loss and accidental damage of sports equipment.

Handle gear locally with common-sense protections. Use padded roof racks and secure straps for shuttles and avoid letting grit sit between plate and mast connections by rigging on soft ground or a mat groundsheet. Separate sharp items and surf wax from foil wings to prevent dings. Do a quick hardware check before every session.

After travel and sessions, rinse thoroughly with fresh water, dry completely and inspect for corrosion. Retorque bolts to spec and lightly lubricate stainless fittings with marine grease where needed.

When in doubt, ship gear ahead via a specialist sports freight company, especially on multi-leg trips or tight connections. Travel light when possible: one stable travel board and a compact foil set reduce handling risk and simplify logistics. Plan, document and pack with protection in mind and you’ll cut downtime and keep your kit surfing-ready when you land.