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We focused on tools that would be useful to a commuter—someone trying to use a bike as a functional way to get around town, as opposed to riding recreationally (road biking and mountain biking). That said, it’s a wild and wooly bicycling world out there, and the streets are packed with so many different bikes, all shapes and sizes, new and old. Customizing your flat-fixing kit has advantages over buying a preassembled kit that always contains a tool (or two or three) that’s a piece of junk, or you don’t need. Or it’s missing something you do need. If you build your own kit, at least you know everything works. And you can add only what’s necessary for your specific bike without ending up with stuff you don’t need.
As you mentioned, it is surprising how often you can get multiple flat tires on while riding, particularly on longer sprints. The tip about bringing a patch kit in your bike repair kit can be incredibly helpful if you’ve already had one flat tire. I agree that all you listed seems like an awful lot to carry, but it’s always better to be safe than sorry, isn’t it?
We like, and recommend, the Crankbrothers Speedier Lever. If you have to pick only one, go with the Pedro’s, but if you want a backup or have some hard tires to unseat, Crankbrothers is a great choice. It’s only one lever (as opposed to a set of two, like the Pedro’s) and it’s longer, so we didn’t pick it over the Pedro’s for portability reasons. But it’s an excellent tool. It has a wide handle you can grip with your whole hand. Like the Pedro’s, the tip is the right size and shape to prevent slipping and stay in place, and the shape of the handle happens to protect your knuckles if you do slip. Even in situations where I didn’t need it, I liked having it because it made me feel like a pro.
There are patches that don’t require vulcanizer—the infamous peel-and-stick. One brand, the Park Tool GP-2, has some genuinely enthusiastic endorsements, so we tested it. I applied Park Tool patches to four different tires, at three different psi levels (60, 90, and 120). Three of the four didn’t hold—two released within minutes. The fourth deflated overnight. I redid the test, but repeated a second time, they all leaked within a day.
Broadly speaking there are two major wheel sizes – 700c for road bikes and 26 inch off-road wheels. However there are a whole variety of older, less common wheel sizes and of course fold up bikes have much smaller wheels altogether. Repairing a puncture is not an emergency! It’s a basic procedure that every cyclist should be able to to perform, but doing it correctly involves more steps than many people realise. Wheel building is often seen as the most artful skill in bicycle maintenance, and separates the professionals from the amateurs but that doesn’t mean you should consider it out of reach. Truing a slightly misaligned wheel is a cycle maintenance job that almost any cyclist can perform.