I have traveled a lot by airplane with my Dahon and my Swift. I went to an Upholstery shop and had a bag made for it. It cost me $100 out of very heavy cloth. I lined it with a cut up mattress topper pad (like an egg crate). It is oversize but I have never been charged for it. I don't pack much other stuff with the bike so it weighs about 30 pounds. Getting my Dahon MU to fit in a standard large legal size suitcase is a lot of work---I had to take off the fork. In my bag I just remove the pedals and the rear derailleur ( I don't want it bent). If you are not carrying tent and cooking gear it is real easy to do on virtually any folder. Have fun...