I wanted to get my Dahon Speed D7 back from my mother's place in Ontario so my GF can use it. I almost didn't bother due to the hassle packing it for the flight and the cost of flying with a bike since I wasn't going to get it under the over sized baggage limit.
At the last minute I said what the heck and just threw the Dahon in a DIY box with no care or special effort.
I took it to the airport and Westjet didn't ask me any questions about what was in the box. They just directed me to the over sized X-ray machine and that was that. No extra charges nobody cared what was in the box.
Although the pathetic box I used got beaten up [not the airline's fault] the bike arrived unscathed.
I'm not a huge Dahon fan, but this bike has one advantage over other folders - it's paid for!...