1. Get a hard storage trunk. Typically these can run $50-$100. Hard plastic sides is what you want. The max dimensions on most airlines is L+W+H=62 inches maximum (IE, the length of a side plus the width of a side plus the height of a side total 62 inches or less).
2. Pad the inside with clothing and stuff. Wrap the head in a trash bag, but don't tie it closed.
3. Get a TSA-approved lock for the case. You can tell what locks are TSA-approved because they have a red diamond on it.
4. If your storage trunk doesn't have a handle to loop the baggage ties to, pack zipties and loop one around the chain of the lock.
5. Buy a roll of "Fragile" stickers and put them everywhere on your case. It's a longshot whether it effects the case treatment or not, but when I came back to LAX from Rainfurrest, my suit case was late to the baggage claim because it was thrown with officially-marked fragile boxes.

Hope that helps!

Thanks! do you have any examples of what trunks to use? or should i just google search them?

This isn't exactly what I got, but it has similar dimensions: http://www.amazon.com/JTT-Storage-T.....=storage+trunk

Another helpful thing to suggest is to include a note explaining that the suit is an expensive piece of art that was packed a certain way and should be re-packed in the same way at the very top of the packing. This is in case your suit case gets a random TSA search. Be polite in it and include contact information.

action packers are really nice for transporting a suit. you can lock it up so nothing gets tampered with and it's nice and strong! (especially if it's being thrown under a plane)

What size would you Suggest for partial suits? to possibly hold two at one or even single?

I Want to use the 24 gallon one but the dimensions will be over 62 inches by one inch. is this what you use? these rubber made boxes look freaking awesome and tough but 8 gallon ones are not goin to cut it i think unless if i pack two. x.x

I use the 24 gallon. they may be big but it's always nice to have a little extra room in it :) they may be a bit pricey depending on where you get them, but they last a very long time. I would assume you could fit two partials inside of you wanted to as well.

And you had now issues with TSA or airlines with the size?

It all depends on the size that they say. if they have a website it should show a size chart