Dear CR List,
I always respond when asked: What is in the box? Exercise Equipment
I have yet to pay extra fees. As mentioned in another posting. If you make a separate box for your frame (no fork) and another box for wheels, fork, and touring equipment no special handling is required.
Just use the compact Park headset wrench they sell with 32 mm and 15mm for assembly and disassembly.
The key is to make sure your boxes have no special handling requirements and fit on the conveyor belt and through the security scanners.
I just got back from a bike tour dealing with Canada North, Air Canada and United Airlines with NO extra fees. (Inuvik to Dawson City on Dempster Highway, 8 days 450 miles of gravel. Dawson City to Whitehorse 350 miles in 3 ½ days asphalt, all on non-KOF Bruce Gordon Rock and Road)
Make sure the wheel box is less than 50 lbs. As overweight charges could be applied.
Also take advantage of carryon baggage not being weighed. I often fill my Ortleib Panniers with heavy food with bear container and sleeping bag and use as my carryon.
Cheers,
Tom Hillman
Modesto, CA USA