There is a real break in price when shipping FEDX. The take the Length + 2x W+2x H to determine size. If you can keep the size under 130" it will be substantially lower. My wife's bike with couplers just met the 130"= and it shipped from Oregon to Michigan for $60. My bike which I had a hard time keeping under 160" cost $160.
All our empty panniers, some tools and water bottles are also in the boxes. As long as it does not go over 50 lbs., the price did not vary significantly. UPS prices were very similar. It was still cheaper than the airlines that we looked at.
We just shipped these last week for a tour through Michigan and Canada that we are starting Saturday.
From the FWIT Department: Handling the other gear is always a challenge. This is a method that has worked well for us regardless of the mode of transportation. We originally started using it on trains, but it also works well for air travel.
This happens to be an Amtrak bus, but we are using the same setup for our flight tomorrow. The bikes and empty panniers are in the boxes in the cargo compartment. All our other gear (full camping gear included) is in 2 very lightweight duffle bags and our rack packs. The duffle goes as checked baggage, and the rackpack and bar bag ( holding camera, tickets passport etc) as carry-on. Also by checking baggage things like my Swiss Army knife, pointed tent stakes, chain oil etc does not get held up at security. The duffle bags are rip-stop nylon, and while looking fragile have been on several flights, and numerous trains and buses. I hope I can say the same thing tomorrow afternoon
Sometimes getting a bike and gear through a busy airport can be a challenge.