Back in March I purchased the Thule Bike Case available at nashbar.com. Got a great deal on it since they were having a 21% off sale. I was a little leery of it, but once I recieved it I was pleasently surprised on how durable the plastic was.

This past Memorial Day weekend I packed up my 2003 Trek 5200 in the case and checked it with Southwest Airlines. They charged me $50 -- good deal! Like you I was concerned from the moment I checked it to the moment I recieved it on the other end.

It arrived all in one piece and no signs of damage or even TSA opening the case and inspecting it. I was really concerned about TSA inspecting, because I figured once they opened it they wouldn't know how to put everything back to how I packed it.

Another thing to think about is that you got to realize that these bike case weigh around 50 lbs when packed with a bike and it's kinda hard to throw around a 50 lbs package. I'd have to image that the baggage handlers just drop it on the conveyer belts and then just slide it into place on the plane.

Also, if you can try to book a non-stop flight to limit the times your bike case is being loaded and off loaded.