Originally Posted by Steve_sr

I'll have to see how everything fits in the box before making my final decision. I will be constrained by the Air New Zealand supplied box for the return trip which is "only" 56" x 31.5" x 12".
-hey there, I got busy and forgot to answer these questions.
re the "Air New Zealand supplied box for the return trip which is "only" 56" x 31.5" x 12". Translate the inches to cm and you can compare it to my box in my photo with the dimensions in cms

One potential issue is bottle cage interference if I put the rotor inboard for protection.
-Ive always removed the bottle cages, and why I often add in a full size 4mm allen key to make it faster to loosen and tighten each bolt (rather than my multi tool one, its more finicky rotating in a confined space of the cage.
-I'd be hesitant to put the disc where it could do a number on your frame is the wheel came loose. I find the disc protector to fit flush against theinside of the box, cushioning blows pretty good. But I guess taking off the rotor is relatively easy, just make sure you have the torx tool with you.

This is a supported tour but I will have to have them carry (with my luggage) all of the packing "bits" for the return trip packing at the end of the tour. I am planning on removing the RD and tying it to the frame so no possible damage. Chain will be off as well.
-carrying the bits in with your clothes is pretty easy. Doesnt take up too much space, and are light. Heck, I carried my pieces from Mexico to Costa Rica just so I would have some for the return trip, but I had ample room in an extra bag on top of my rear rack, kind of an overflow bag or for light stuff.

BTW, what is that black plastic piece in the upper right of your photo? RD protector? How does it fit?
-yup, thats it. Well designed, it fits over your quick release area and just inside the dropout, and the flat part goes against the inside of the box, taking forces that can go in that direction, pretty effective I find. (touch wood!)

Local REI has a big box of this stuff which I have already visited a couple of times.