Originally Posted by
SparkyGA
Cardboard box works just fine. I boxed mine up 5 times this year in various boxes and had no issues problems whatsoever. The boxes are usually free from an LBS. I grab one from an LBS, fold it up as much as possible, shove it my pannier and cycle to the airport/train station where I do the disassembly game. Get the biggest box you can get ahold of too, box sizes do vary quite a bit.
Best tip is throw all your gear inside the bike box. Saves you a piece of luggage to check in and protects you bike

Worked great for me. Put my bike tools, bottles and panniers in the box for 44 lbs.
Bike shops throw out bike boxes everyday.
Plan on it being laid on its side in the plane.
Protect the derallier and place a spacer inbetween the forks.