This thread is kind of long to read it all so someone probably covered this already. Actually a cheap cardboard bike box works pretty good if you don't want spring for one of those expensive bike suit cases; then depending on where your going you can throw the box away and get another one later if you can't store the box anywhere. No matter what you use buy some foam pipe insulation and cut lengths to fit each frame tube including seat stays and fork and headtube, then just cover all the tubes. Then wrap all loose parts, like pedals, seat and handlebars with bubble wrap. All this foam and bubble wrap crap will help prevent scratches etc.