Join Date: Jul 2010
Location: Victoria, Canada
Bikes: Cannondale t1, Koga-Miyata World Traveller
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Interesting project. I can't see a single wooden box loaded with a tandem making either the airline max weight, or the max dimensions. A tough call. How often will you use the travel case, or cases in the next 10 years? If you only intend to make a couple trips, the extra fees for overweight or oversize luggage are insignificant in the long term.
My personal preference would be to purchase 2 SERFAS cases. You and your stoker can each check in one at the airline. And if you have a scale handy, you can pack your stuff in the boxes, but not exceed the max luggage weight.