04 Break Away (like the paint much better than the current black/white)
DA9 (Tom put 7800 rear derailleur and brakes on it... nice)
FSA SL-K Crank
Terry Fly saddle
Custom wheels - DA hubs, Sapim CX-Ray spokes, Velocity Aerohead/Aerohead OC rims
Easy to assemble out of the travel case - took me about 45 minutes taking it slow and reading the directions step by step. I figure I can drop 15 minutes easy.
How long to break it down into the case? Assembly is often faster for me, too (I have two S&S bikes). I can do it in about 15 minutes. Breaking down, especially if trying to get everything in there and beef up the weight to regulations by sticking other stuff in there, can take close to an hour.
We'll see about full-up packing - probably will do it at least once in the next couple months before packing it out to "home" in Greece. I'll probably do the same - take lots of time to wrap/pack it up safely. It doesn't require a lot of puzzle-piecing, though.
I think I'll be able to get the assembly time pretty quick with more practice. Tom Ritchey has a couple pretty cool videos online for buildup/takedown:
The suitcase is technically 3" over the 62" l+w+h airline limit, but I'm not expecting any problems.
It has a hard ABS cup in the bottom for the cassette, which is very nice, and the ABS frame for the suitcase disassembles with pins so that you can fold the case small enough for an airport/train station locker.
The new BAB cross frame is out now also, which would make an awesome touring bike - eyelets for racks and canti brake bosses.