Originally Posted by Dave Hickey
I use a standard Samsonite F'lite for my Bike Friday. BF wanted $250+ for their version. I bought the Samsonite in Ebay for $100. I also spent $10 for some felt fabric to wrap the parts while in the case...
I don't recommend building a case/box. An old suitcase will be fine.
My Samsonite gets searched about 1 every 5 trips... A homemade case/box will virtually guarantee a TSA search every time(assuming you're in the US).
Have you recently used the F'Lite on a domestic flight and was the fact that the suitcase is 2" over the 62" limit ignored at check-in. When you declare the value which I assume is well over $1k for a BF, do you tell them that it is for a bike.