Hi Mike,

For the last year or so I have used the Ruster Henhouse (which is claimed to be under 62 inches) and never had any questions.

Prior to that I traveled at least a dozen times as GS in Business Class with a large box (tricot style) and never had anyone even suggest a fee.

The Ruster takes some knowledge of bike assembly -- you have to take off the bars, pedals, fork, and derailleur. But they have a good video that shows you just how to do it. I can pack or unpack a TT bike in ~20 minutes. SRAM powerlinks (and others) have made things a lot easier, since they allow you to remove the chain and the $600 Etap derailleurs and stick them in your carry-on. I now prefer the Ruster to the tricot style case, because it's much easier to roll around and fit into rental cars and public transit.