I have bought a number of swords over the years primarily from Hong Kong, Singapore and India. I typically checked them in seperately as I did not have any check in luggage either. I had the swords heavily packaged in bubble wrap. I purchased additional insurance as these were antique swords from the airline (BA and CX and AA) from the airlines i was flying on. Declared the sword as a "weapon"at check in. Then mentioned it very clearly (itemised) on back of Customs form for US entry dox. I have never had a problem bringing hese in using the above preocess. BTW this worked pre andpost 9/11. Hope this helps. Good luck.