Answers to my questions..

I had a bag made for my Dahon. I cut up my mattress topper (waffle foam style) and put it inside the bag. I unscrewed the rear derailleur from the frame and put a plastic bag over it with a rubber band holding it on. I slid the bike and everything except the pedals into the bag. I had a strap sewn onto the outside of the bag all the way around with it stitched in every 6 inches leaving a bunch of hand holds all around the bag. After putting the bike in the bag I tied a rope through the straps to cinch up the bag around my bike.

It is certainly oversize but I have now flown with it 3 times and no oversize charge. Weight is under 30 pounds. 5 minutes to load or unload.

I put my pedals in my carry on so if they ask what is in the bag I can honestly say "Bicycle Parts" no it is not a complete bike. I am not going to lie to them. My pedals are the dual function Shimano A530 which can be installed or removed with an 8mm allen wrench---lighter and handier than a pedal wrench.