You can go the cardboard box route - most bike shops will give you one of the boxes their new bikes come in. That's what I did on my first tour...
The box included a stiff sheet of cardboard that slipped inside and matched the size of the box. I used zip ties to attach the frame to that so it wouldn't shift inside the box. Another thing I did was attach some pipe insulation (from the hardware store...) to the frame, just a little bit of protection.
On the bike fee front, I always had to pay in the days that I traveled with my diamond-frame bike - that's why I bought a Bike Friday, which fits in a legal non-oversized suitcase.
--- Denise



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At least I don't have to think about that until 2007!
I wouldn't want to deal with storing a bulky bike case either. My goal is to keep life as simple as possible. Yep, call me lazy.