Well the secret is to split the bike into two (supercute!) boxes. Both under 62 linear inches.
Box #1 = frame only. It's a parallelogram shape and you have to take the fork off. I ride a 54cm frame.
Box #2 = wheels only.
For domestic races, I'll ship my race wheels ahead of time to my homestay, hotel, or local bike shop. Then I fly with the frame...train with the training wheels up until departure, no training time lost! International races, I fly with both, throw my clothes in the carry-on or backpack, everything else in the 2 boxes--you just have to make sure that both are under 50lbs which is pretty easy peasy. With all my gear, the frame box is still under 40lbs:
Boxes are made out of cardboard bike boxes, colored duct tape and cute stickers/fabric/etc. The frame box opens up like a pizza box so the walls are essentially double reinforced. Straps are big 2" nylon ones with plastic buckles. Always decorate the boxes with super cutesy stickers or graphics and never never never admit that it's a bike! I like to tell them that I have paintings in there. I am never dressed as a triathlete at the airport and keep my helmet hidden inside my backpack or carry-on.
Also make removable wheels out of caster wheels at Lowe's/Home Depot and velcro. This greatly helps when wheeling your crap through airports, but I always take off the wheels before checking the box(es) in because they get banged up. Velcro, duct tape, & cardboard are the key here. Staple gun and glue gun are excellent sidekicks.
I realized after the fact, that splitting the frame and wheels is the same idea as the Hen House softbags...except in sturdier reinforced cardboard boxes. One could argue that you could still throw the race wheels in a softcase and take them on the plane. I haven't done it, I still feel like it screams "I'm traveling with a bicycle because what else could these be but wheels???"
Besides, half the fun of flying your bike for free is MacGyvering your own box! Oh yeah and when checking in the frame box, make sure to orient it so that it's sitting on the longest dimension. The 4 sides are all different lengths but it looks bigger or smaller depending on which side it's sitting on. Sneaky sneaky!
And no, I don't ever get charged for traveling with my bike.
xox
Wongstar
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:: I came, I saw, I conquered. then I ran out of money, crashed into a car during an Ironman, and now work a bad-ass job making prosthetic legs for wounded warriors. ::
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