I've managed to squeeze 59# into a 26" Samsonite Silhouette. Of course, it was only about 40# before I was given a bunch of stuff at corporate to take back to our satellite office. So, I paid the $25 overage charge (Delta) and then expensed it.

Now when I attend training classes in other cities or otherwise have lots of paper to haul home I just ship home instead.

And I never volunteer to take stuff back with me anymore... been bitten by that question before...

Oh, and the "weighing yourself on your bathroom scale" is the best method I've found... but I did see a scale at IAH at the Continental Express check-in counter last week (next to the carry-on sizer).