Travel guideHow to pack your windsurfing kit safely for the flight

Stephan Gölnitz

 · 04.06.2026

Maximum protection: with cardboard wrapped round the rails, a trapeze at the stern, a homemade airbag at the bow and the sails on either side, nothing should go wrong.
Photo: Stephan Gölnitz
Anyone who flies off on holiday with their own kit is familiar with that more or less nagging fear that their board bags might be handled too roughly at the airport. We’ve put together some packing tips that will significantly increase your chances of unpacking your kit undamaged after the flight.

Rule number one: No sharp-edged parts in the bag without padding. On surf test trips, the fins do come with the board, but they’re well packed in cardboard. Nevertheless, on one occasion a fin screw came loose and somehow found its way under the board, where it left a ‘memorable’ mark in the laminate. On private trips, fins are even better off in a travel bag.

Packing items such as harness hooks, foot straps, the mast base and extension, as well as the harness lines, separately also reduces the weight of the board bag on the scales, where, as we all know, every gram counts. The weight limit usually only allows for one board, two sails, two masts and a boom. “You really shouldn’t go over 32 kilos,” advises Oliver Hilf from Surf & Action. “Any more than that isn’t allowed. I aim for around 28 kilos if possible. If the bags are at the limit, the loaders get fed up, and then, I’m afraid, there’s a greater chance of one of these things falling out somewhere.” In the worst-case scenario, it could take a nosedive onto the nose or tail – that’s where the most damage occurs during air transport.

Cardboard airbags

However, with a bit of cardboard, you can stick together an effective airbag, as shown in the pictures above. This is where Rule 2 comes into play: brown adhesive tape might be fine for DHL parcels, but it usually leaves very nasty sticky residue on the board and on bags when you peel it off. Sturdy (paper) masking tape is much better suited to the job.

Thick cardboard around the rails, with a bit of overlap at the front and back, and masking tape – that should ensure everything arrives in one piecePhoto: Stephan GölnitzThick cardboard around the rails, with a bit of overlap at the front and back, and masking tape – that should ensure everything arrives in one piece

The packing experts at board manufacturer Cobra also protect the edges all round with cardboard. If you leave the cardboard protruding at the front, it also acts as a handy buffer for the tip of the board. It’s important to keep an eye on the overall length. “Over 2.40 metres – that’s my magic limit – you can’t check in any luggage at all with Turkish Airlines, for example,” explains travel expert Oliver. Inflatable roof racks Once inflated, they can be strapped or taped to the front of the board, meaning they don’t weigh a single gram more.

Good seatbelts, bad seatbelts

Would you use your €300 Neo as a work mat when changing tyres? If not, then it’s not recommended as padding for the fork, for example. The harness, on the other hand, is sturdy, and hip harnesses (without a hook plate!) often fit perfectly in the bag at the rear.

When packing, you can first place any spare dividers from the bag underneath the board – or even fit two masts side by side in the padded sleeve. Next, place the sails on top of the board, with the boom on top of them. A swivelling head piece is useful, but it mustn’t press down on the board or the sails under any circumstances. Often overlooked: make sure everything is securely strapped down inside the bag so that all parts and padding stay where they are. Using long straps, the board bag can then be wrapped around the outside – starting from the front carry handle – like a roulade and tied off as a short, tight bundle. This gives the contents a secure hold, provides the loaders with additional carrying options and makes the bag appear smaller – which is no disadvantage at check-in.


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Stephan Gölnitz

Stephan Gölnitz

Deputy Editor in Chief surf

Stephan Gölnitz comes from Bochum and had Holland as his home windsurfing territory for many years before moving to Munich in 1996 for the job of test editor at surf magazine. The materials engineering graduate worked as a surf instructor on the Ijsselmeer during his studies and competed for several seasons for the Essen sailing team in the Surfbundesliga and the Funboard Cup. He completed a traineeship at surf-Magazin in the test department and since then has actively accompanied almost all tests on the boom and for more than 10 years also as a photographer. Stephan has covered many thousands of test kilometers, mainly on Lake Garda and in Langebaan, but also in Egypt and Tobago. He gets his hands on over 100 new sails and boards every year as his company car. Privately, he prefers to surf with a foil on Lake Walchensee or “unfortunately far too rarely” in the waves. SUP is Stephan's second passion, which he pursued for several years at numerous SUP races. Today, he prefers to paddle on river tours with family or friends - even for several days.

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