Packing, shipping
 

I have a 46cm Surly LHT touring bike. I am planning a trip to Hawaii from the southern US. What is the cheapest way to get bike there? The bike can be broken down completely. I am extremely comfortable with any mechanics to put it back together. I am wondering if I ship it in smaller boxes, that I can get under the dimensional guidelines.
Ideas welcome.

I was able to put my L size Cannondale T-1 into a small box.
http://i256.photobucket.com/albums/h...ox/BikeBox.jpg

http://i256.photobucket.com/albums/h...0Box/htonj.jpg

You might be able to break down a 46 cm to get it inside an airline legal box (L+W+H <= 62"). If you can get it that small, $35 each way for a second checked bag would be the way to go.

Remember to put spacer blocks in the dropouts to keep the frame and fork from getting mashed closed.

Edit: And in the brake calipers if disc brakes are fitted and the wheels removed.

If the airline bike fee is $50, like Virgin and Jet Blue last I checked, it may not be worth the effort taking it apart to get it on as regular baggage.

Go to a bike shop and ask to see a boxed bike as it comes from the factory. EVERYTHING that the factory does - do that. If they didn't think that it was necessary, the factory wouldn't do it.

Here's what Rivendell Bike does: