mimitabby-
If I may ask, what other problems has your DH had that cause him to not want to fly with the bike? We may still have the option of returning the bikes, so I'm trying to gather as much information as possible to make that decision.

I do want to be able to travel with it, and it's by far the most expensive bike I've bought, so I'd rather know sooner than later that it won't work for me...

The noodle/barrel adjuster of the rear brake actually hits the frame when you brake still.

It is a pretty bike, though. Most of their problems (thus far) seem to have been either 1) adjustment or 2) packaging problems. So, maybe there is hope...