I am buying a used BF Pocket Rocket and need a case. Is the Sampsonite F'lite 31" the case of choice? Have any of you had any issues with being charged a fee for oversized luggage with this case at airports? What packing materials and tools should I buy/do I need?

Get the F'lite..Don't bother with the BF case... I bought mine on eBay for less than $100.

The case has never been charged an oversize fee... As for packing materials, pipe insulation, foam rubber, and some towels are all that I use... You will need a crush protector... I bought mine at Excel Sports(I believe it's listed with the Richey Breakaway case). It's basically just a PVC pipe with two flanges

I have the original (earlier version?) Samsonite that came with it... just a single wall plastic case but good enough. I think they had another available at some point (Carlton?). From BF they come with tools and packing materials... 2 or 3 screw-in posts to keep the frame from moving, pvc tube + plates to keep the case from getting squished, some felt bags and plastic covers for stuff that needs to be removed (stem, bars, hoods, R crank, pedals, seatpost, skewers, etc) and tools. Plastic stay protectors (or tubing insulation) are a good idea, as are velcro straps to keep it all together in case TSA needs to open it for inspection (and get it back in). A few allens and pedal wrench are all you need and they supply a hs tool for some reason. Go to their website or contact them, they can help you. One of the whole points of BF is to avoid oversize charges.

Get the F'lite..Don't bother with the BF case... I bought mine on eBay for less than $100.

The case has never been charged an oversize fee... As for packing materials, pipe insulation, foam rubber, and some towels are all that I use... You will need a crush protector... I bought mine at Excel Sports(I believe it's listed with the Richey Breakaway case). It's basically just a PVC pipe with two flanges

Thanks Dave. Is this the crush protector? http://www.excelsports.com/new.asp?page=8&description=Compression+Members&vendorCode=SANDS&major=9&minor=1. Is one all that I need?

That's it.... I bought two to be safe but you can get away with just one...I have packing my BF down to a science and can do it in less than 5 minutes... It's really easy...Knock on wood, I haven't experienced any damage yet...

The TSA will open the case so make sure that any thing like tools are in a clear baggie...Don't bury small items in the bottom of the case. Put them on top so the TSA can see it when they open it. As near as I can tell, I've never had them remove the bike from the case. CO2 is a big no no on airplanes....Some BF owners use a frame pump but I bought a threadless CO2 inflator. I stop at sporting goods/hunting section of Walmart/K Mart, etc..at my destination and buy a couple of CO2 cartridges for less than $5 total... Threadless CO2 can be found anywhere that has a sporting goods section

I hope you enjoy your BF..I sure do like mine. I'd go insane with all my business travel if I didn't have my BF....