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Originally Posted by oliverbogler
I do need to take my MacBookPro though, and am quite worred that I'll have to check it on the way home! Anyone ever done that (sorry, off the topic of iLiads...)
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When I need to check my gadgets I use what I call The Ugly Box.
You take your items to a packaging store and have them custom build a box for you. Or if you are handy you can buy the materials and make it yourself.
Up front you need to decide which approach you wish to take as The Ugly Box comes in two basic models.
The "I'm just a bit paranoid" model.
Select a box that is capable of allowing 4 inches of foam on all sides and blow two plugs of triple expanding foam into the box. One is allowed to glue itself into the bottom of the box with a layer of plastic sheet on top. The devices are placed inside on the sheet as the foam is still rising. Another plastic sheet is placed over them and pulled back up the sides and out of the box. More foam is blown into this plastic sheet to make a second plug of foam. This plug can be removed because the plastic sheet covers all sides. The foam self molds itself to your gadgets and holds them like a lovers hug.
The second model is for those who are feeling really paranoid because they have personally witnessed an airline baggage handler stand on the ground and toss packages into the plane. Have them hit the cargo hatch and fall back to the ground. Grab them and throw them again, and take 4 tries to get one package into the plane...
For this model you start with the first model.
Once that box is created stick *it* in a box that allows 4 inches of foam on all sides.. repeat process.
If you go to a packaging store and request the really paranoid ugly box they may tell you are really paranoid. Just agree with them and they'll make it for you.
One thing to be aware of with the really paranoid ugly box, you may have to accept more foam than 4" of foam depending on the available boxes. :P
Be careful not to go too crazy. If you make the box too gosh darn big the airline will charge you for oversize and getting it into taxi/rental cars gets harder.
When you get back you can store the ugly box and use it again. When the airlines dent the corners, tear strips off, poke holes in it, no tears come to your eyes. Its an ugly cardboard box, not Gucci or Prada.
If the TSA or Customs wants to inspect The Ugly Box, there is always packaging tape lying around to reseal and/or repair ugly box. Ugly Box requires no instructions on opening and closing. The foam plug is difficult to pull out, which means nothing gets lost even if the TSA doesn't tape it closed again.
The ugly box has another feature. If needs be, you can UPS or FedEx the ugly box.
I also appreciate that the ugly box is ugly. Ugly box is often ignored by the admiring and covetous eyes of people whom might wish to make ugly box (and its contents) their own. Charcoal is useful for artificially applying the grungy look the airlines will apply to ugly box for you on its first trip. Or turn children lose with felt tip markers for even better camouflage.