1. Choose your airline carefully. Some charge lots for bicycles, some charge nothing, and most charge somewhere in between.

2. Read this to get an idea of what each airline charges, then check the airline's website for more detail and any updated information: http://www.ibike.org/encouragement/travel/bagregs.htm

3. Read the information about weight and size restrictions for bicycle boxes ... be sure to read the bicycle section, not just the oversized and overweight luggage sections.

4. Get to the airport very early, be happy, friendly, polite, helpful through the process.

5. Cardboard works just fine ... it can help to wrap the bicycle in foam or bubble wrap and to ziptie parts together. Also be sure to tape smaller items to some part of the bicycle, or put them securely into the panniers you're using as extra padding. There are holes in cardboard boxes and small items can drop out.

6. If you really want a hardshell case, rent whatever your local bicycle shop has. Mine had a $5 rental fee ... I could do a lot of flights before I came anywhere close to the full price of a hardshell case.