The 62" rule stumps me. So there are bike boxes that come under that number?
My packing problems are increased because I have a recumbent, requiring either one very large box, or two somewhat smaller boxes. I am using a regular bike box for everything but the frame, for which I am using a SporTube. I will have one and my wife will have the other. The upside is that I can pack everything in these two cases and not have luggage (I think). While packing I will use a scale to make sure I don't go over 50 pounds with either case. Who knows what the airline will think about one bike split between two cases.
I can borrow a tandem case, in which my bike fits perfectly, but the stupid thing weighs 38 pounds empty!
You can't fit your helmet in your bike box?