Busted! How to ensure your luggage survives a trip

One minute I was rolling my carry-on bag along the concourse floor at Ronald Reagan Washington National Airport. The next, I was arguing with a useless box on wheels — and dreading what would happen to my back if I had to carry it.

The extendable handle on the bag was stuck, and no matter how hard I tried, it wouldn’t retract. I had to haul the bag on the plane without the help of wheels. With my bad back, I knew I would feel that the next morning.

And I did.

So here I am, shifting uncomfortably in my ergonomic office chair and heavily medicated, wondering: Am I the only one this has happened to? How often does luggage break?

What happens when it does?

Turns out it happens a lot. There are no statistics on luggage failures of the type I encountered — broken handles, busted wheels, screwed-up zippers — but plenty of stories.

“My bag broke in the middle of the trip,” remembers New York-based comedian Dan Nainan. “The handle broke off. It was awful.” It wasn’t funny, either. But lucky for him, the bag came with a 15-year guarantee, so he sent it back to the manufacturer and had it fixed.

My carry-on bag came with a warranty, too. Not a bad one, but there’s some fine print that may make it difficult to file a claim (it doesn’t cover wear or damage caused by abuse, mishandling, accidental damage, inappropriate selection, or carelessness caused by an airline). But since it’s a sample, I felt a little awkward about saying anything to the manufacturer.

As to the question of what happens — well, that’s why you’re still reading this story. Here are four luggage horror stories, and some tips on how to cope with them.

1. The stuck handle
I’m not the only person with a stuck-handle problem. It happened to Charlotte Tomic and her Hartmann luggage on a recent flight. “I guess these things happen with time, or if you put something too heavy on the handle, like a laptop, maybe,” she told me. “I’m not sure why these retractable handles malfunction, but it could be very unnerving.”

Tell me about it. If a handle acts up mid-trip, you have a few options. If you’re at the airport, your airline might insist that you gate-check the bag. (Be sure to remove any valuables.) An extreme option is buying a replacement and abandoning the bag at the airport. Fortunately, I managed to retract the handle so it would fit in the overhead bin, but carrying the bag around was no fun.

2. The busted zipper
Face it: zippers aren’t meant to last forever. And if you push the limits of your luggage, it will eventually push back.

Author Nancy Redd, a frequent flier, likes to stuff copies of her book in her carry-one bag. Her luggage can take only so much, and has given way a time or two. “The last time that it happened and I wasn’t able to obtain a new piece immediately for less than highway robbery at the airport, I just asked airport employees for some of their ‘fragile’ tape and wrapped it around my luggage as a quick fix to keep everything stored until I could obtain a replacement at my destination city,” she says. “It totally worked.”

3. The broken handle
Sharon Flank remembers a “major malfunction” with her luggage on an international trip. “The handle broke off my suitcase as I tried to haul it up the Metro stairs in the rain in Paris,” she says. “I was pretty miserable.”

Handles are not easily replaced on the spot, but eventually, she found someone to repair it. “Now I always keep a long strip of Velcro in my carry-on — you can use it as a makeshift handle,” she says. That’s excellent advice.

4. The flat tire
Most carry-on luggage comes with wheels, but no matter how industrial-strength they appear, they are disappointingly mortal.

The wheels on my last bag died slowly, over several trips. First the rubber became frayed, and then it peeled off until the bag made an annoying rat-tat-tat when it rolled on the concourse floor.

Fortunately, I’ve never had a wheel come off. I retired the bag before that happened. Luggage wheels are not as easily replaced as roller-skate wheels. If they were, we wouldn’t be having this conversation.

There’s only one certain way to avoid the broken luggage problem, according to Jeff Boyd: Don’t carry any. “Send your luggage ahead,” says Boyd, who is the president of Luggage Free, a baggage shipping service. (A service like his will fix any luggage that’s broken while in its care at no extra cost, whereas airlines don’t generally fix broken zippers, handles or wheels, he adds.)

That’s one solution, but another less extreme on might just be this: Check your bag for wear and tear before your next trip, and for goodness sake, don’t overpack.

Your bag will thank you. Your back will thank you.

(Photo: M.V. Jantzen/Flickr Creative Commons)

  • CmC

    My husband calls me a over-geeky packer, but I travel with small bags (18-20″) and I use the eagle creek packing cubes for everything. In addition, I carry this flat folding nylon suitcase at the bottom of my bag. I also use a neon pink and green ugly luggage strap from the days when I used to check. If my bag breaks, the cubes make it easy to corral my stuff. If the bag zipper breaks, the cubes plus the strap will hold together. If a more catastrophic failure happens, the spare folding bag will get me to my destination. I even checked the thing full of coats once and it survived just fine. (I admit that I really carry it for shopping purposes).

  • SirWired

    The luggage forwarding services cost a bloody fortune. I guess they might make sense if you are trying to check three overweight bags and the airline wants even more of a fortune, but other than that, I’m coming up blank for real uses for this service. I know the airlines aren’t perfect in delivering bags ontime, but for the cost of these shipping services you could pay for an entire new set of stuff after not that many trips. In any case, in my personal experience, the airlines aren’t any worse than UPS or FedEx, which is what gets used to ship your luggage with these places.

    On another note: Briggs and Riley luggage. A REAL lifetime warranty. NO exceptions. Zippers wear out? No problem. A conveyor monster eats it alive? No problem. Airline run over it with a baggage truck? No problem. Wheels wear out? If you carry a spare, two minutes and a hex wrench fixes it.

  • Cliff Woodrick

    I always carry a roll of duct tape in my suitcase. This has saved me when a zipper failed and I do not over pack my bags. Somehow the cloth by the zipper started to rip and I taped the bag before returning home

  • Joan

    AND check ahead at all airports for the location/s of luggage stores. They are usually some and they can be life-savers.

  • marian levin

    After a flight from Miami to Dorval airport in Montreal on Air Canada I was waiting at the baggage carousel when I saw individual pieces of clothing come down the chute. My first thought was, “oh, that poor woman.” As I watched more and more clothing come down the chute I realized that poor woman was me. Living in Northern NY as I did then, I’d done some major shopping in Florida. The clothes coming down the chute still had price tags attached. Apparently, my soft sided luggage got caught and ripped open on its trip from the plane to the terminal. Most of the clothes were covered in grease and unwearable. Because of the price tags, there wasn’t too much of a hassle with the airline settling my claim. We just had some dickering on the other things that weren’t new. At least I had fun doing the shopping even though I never got to wear the clothes.

  • Nancy Thompson

    Why not carry one of the lightweight water-repellent red/blue/white striped bags? They come in all sizes, are very light, inexpensive, will do for emergencies as well as a luggage strap. I use them for extra destination shopping. Thailand also has quite nice double layer folding bags similar to the tri-stripe ones mentioned above. The only snag is they have no wheels, but as an extra bag for holding stuff when going home, or for emergencies, they are very very good.
    Nancy

  • Ellen

    Ditto on the comment about a packable nylon bag. I carry a large Baggallini on all my trips now.

  • Carrie Charney

    Like Cliff Woodrick, I also carry duct tape, especially when taking my duffel. the cloth near the zipper ripped, I taped it up, and then when I got home, I sewed the tape to the bag. It has held up admirably on many more trips.

  • Ana

    I have had the best of luck getting my luggage replaced.
    Most luggage companies are very understanding, especially if you ask for a replacement PART instead of a whole new suitcase. Usually it is pretty easy to replace the handle or the broken lock (courtesy of TSA!) or if you are not handy, your local repair shop will do it in a jiffy.
    Writing the manufacturer and stating how much you like your suitcase and how much you would like to keep using it is the best kind of compliment there is. Usually they will ship the part for free or for a small fee.

  • Amanda

    Once, on a trip to Italy with my parents, I used my brand new American Tourister bag. I’m not sure when or how it happened, but by the seventh day of the trip, one wheel was totally busted, creating a gaping whole in the bag itself! We weren’t sure where or how it happened – we were with a tour, and our bags had been on many different forms of transportation. We invented a creative solution with packing tape and cardboard, but when we got to the airport for our transatlantic flight home, we spotted those people who “shrink wrap” your bag. Normally, this is kind of a scam, but it ended up working out great in our case! The thing was wrapped up tight, saving my clothes from an oily end on the tarmac. :) It definitely gave us peace of mind on the way back, and my parents (who gave me the bag) called in that warranty first thing!

  • http://www.majid.info/ Fazal Majid

    No luggage, no matter how sturdily built, will ever survive the tender attentions of baggage handlers. To a large extent, you get what you pay for, and inexpensive luggage can end up costing you in inconvenience. I standardized on Bruiggs & Riley years ago because of their unconditional lifetime warranty. When Air New Zealand ripped the bumpers off my 23″ Pullman, I sent it off and in two weeks got it back good as new, the only cost being the shipping to them.

  • http://www.kevin-mccoy.com Kevin McCoy

    Let me add another comment supporting Briggs and Riley luggage. As a touring stagehand, I live out of my luggage for months at a time. It’s in and out of airplanes, tour buses, trucks, taxis, etc. Every year or so, I take the bags in to get repaired, replacing the bumpers that have broken off, the occasional broken zipper, etc. Often times, the repair technicians will replace things that I hadn’t noticed just out of caution. You may still suffer some inconvenience in the moment of something breaking, of course, but they have an awfully good incentive to design their bags to keep that from happening too often.

  • Tina Potter

    I think everyone who has traveled in the last 10 years has some horror story about the airlines and lost bags but add that to the fact your trip is to a cruise and it makes for one heck of a story. My husband an I were leaving out of Fort Lauderdale last Februrary for a 14 day cruise and got to the baggage claim and no bags! Come to find out the bags were still sitting in Atlanta during our transfer and werent supposed to get down to us until the next evening. We weren’t about to miss our cruise so we eneded up having to buy a whole new wardrobe the next day just to be comfortable on the cruise. This was the worst expereince ever! My husband found a service this year through a golfing buddy who uses it to send his clubs out to California ever year (luggageforward.com). They picked up our bags right at our house and the next time we saw them was in our cabin….MAGIC!

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