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.