I have a Thule hard case. I've never flown with my bike - simply too much hassle schlepping it around airports. FedEx costs about the same as flying with it, and is so much more convenient (within the US, anyway). You can have them pick it up at your house or drop it off at a FedEx store; you can ship it right to your destination (if it's a hotel, just let the desk know that it will be coming), or have it held for pickup at a FedEx depot.
Very little disassembly is needed for my case, which is pretty standard. Wheels, pedals, seatpost with saddle still attached, handlebars (with or without the stem), rear derailleur. If I leave the stem on the steerer tube, I have to disconnect the front brake cable; someone with a longer head tube or a different case might not have that issue. All the other cables stay attached. Don't forget to let some air out of your tires and remove any CO2 canisters from your luggage - they're not allowed to fly even as cargo. Buy some new ones at your destination, or you might even find a simpatico LBS that'll let you borrow some and return them if you don't need them.
If you can fix a flat, adjust cables and tweak your fit, you've already done everything you need to reassemble a bike after shipping, with the exception of removing the RD - which is basically nothing. You don't touch the adjustment screws that position it, so you just unscrew the bolt to remove it and screw it in to put it back on. 
Disassembly and packing takes a little while (especially the first time, when you'll want to mark the seatpost, stem/steerer tube and handlebars with inconspicuous dots so you'll know where to position them; and when everything takes longer just because of unfamiliarity), but reassembly can be done in 15-20 minutes, with a handful of tools that you can ship in the box with your bike. Literally. I've done it in the FedEx parking lot.
				
			 
			
		 
			
			
			
				
					Last edited by OakLeaf; 06-22-2010 at 02:07 PM.
				
				
			
			
			
				
			
			
				Speed comes from what you put behind you. - Judi Ketteler