After starting this thread I followed early advice and had a bag made by a local upholstery shop. I lined this bag with a cut up mattress topper (the egg waffle type). I have flown 4 times with it so far and never an extra charge by the airlines. I'm headed to SE Asia and plan to use it again. It is oversize but with my bike and odd gear in it the weight is under 35 pounds. No problem at the boarding counter. They ask if it is a bike and I say it is bike parts---i put my pedals into my other bag. After they ask that ask if it matters if it is a bike or parts. One guy made me sign a release if it was damaged---no problem. I take the rear Derailleur off and the pedals--It can handle a 5 foot drop anywhere on the bag.