Thanks for the suggestions. Before I shell out $400+, I think I'll try packing my Ritchey case the way S&S suggests packing its case, and see if that works better. I've always taken off the handlebars, seatpost and saddle, front brake, and pedals, but it looks like some people also remove bottle cages, one or both crank arms, rear derailleur, and the stem.

charliekeri, I've flown several times with the Ritchey case, and never had a problem with it being slightly over the size limit. I did get asked about the plastic bulge on the side, but once I explained I had bike parts in the case, all was well. I just wish the case fit and protected the bike better, because it's a heck of deal that they throw it in with the frame. How much did you get for it new on eBay?