We travel enough with our bikes that we both have S&S coupled bikes (fit in a 26x26x10 case that, with bike, weighs in at 47.5lbs). We stopped flying Delta/NW because of the rumor that Blueberry mentions although we've never had anyone question anything except the weight of the case. This summer we are travelling again on Delta (only airline that would do the route we wanted). We'll see. But, of course, I'm travelling with "mechanical parts".

That said, I have two things to add to the thread--Southwest was great. Their literature states coupled bikes that are underweight and within size travel as regular luggage. I'd never flown them before (they've only recently stretched to Milwaukee) and it was by far, the best flight experience I've had in a very, very long time. If you can fly Southwest, really consider it. You have to book directly on their site and they charge only $50 for oversized bike boxes.

The second is that we've been flying with the bikes for a while. The bikes always make it (although we've had suitcases not arrive on time). The bikes have have not been damaged. And, thankfully, the TSA has also seen no reason to open the cases and inspect them, either (probably my biggest worry is that the TSA will open, attempt to unpack and not repack correctly).

For some reason, I feel better having the bikes travel with me. There is no basis for that fact. Shipping has its own set of risks. In the end, do the research, and transport the bikes in the way that gives you the best warm, fuzzies.....well, the lesser bad feelings and worries?