Hi List!
I have flown countless times with no extra fees (this is before fuel tax days...). This includes traveling with a Rock and Road Bruce Gordon 700c touring frame, a Whitcomb Road Frame, and a Santana Scandium. Recently a Gold Rush EasyRacer Recumbent. (Arrived with a bike to the Greensboro Cirque three times, with no extra fees).
The key is to pack the frame in it's own form fitted cardboard box. Strip the bike down to only the frame (often I remove the fork, depends on how big or heavy your frame is). Extend around the frame about 1" with the cardboard and reenforce with cardboard with stiffeners internally. Use liberal amounts of clear packing tape (get the good stuff from 3m it is heavier and cuts cleanly). Also I always use a nylon threaded rod with wing nuts to place in the rear-drop out (this is light and can be taken with you on the tour as I often start and finish at different locations).
Place all the rest of the bike and touring gear in a wheel box. On extended Alaska tours I filled my panniers with food and brought them on as "carry-on" to meet the weight restrictions.
Most Airlines have at least a 50# weight limit. I use nylon webbing for support for handlebar bag and use this webbing to make conveinent handles for the boxed frame and the wheel box. Double straps on the wheel box makes it so you can carry it on your back in the airport or bus station (BTW some bus lines Greyhound, Trailways can charge extra for bikes in regular bike boxes, "oversize").
The goal is to be able to check in at the usual front counter and have the frame and the wheel box go down the conveyor belt like normal luggage.
Oh I almost forgot: When asked to describe your luggage respond with "Excercise Equipment" otherwise if you use the word "bicycle" it generates instant fees.
I believe airlines should only charge if your luggage (exercise equipment: aka bicycle) takes extra labor to load or unload. Or if it is overweight.
Happy Touring!
Tom Hillman Modesto, CA USA
B.T.W. The Richey Break-Apart Frame with the trick double seat clamp and small bugle joint above the bottom bracket works really well with no compromise in road handling, some day I want to build a classic KOF custom touring 531 bike with the Richey fixtures....