PS to this thread -
Any other packing tips you might have, please let me know... My checked bag is hitting around 45lbs right now and there is PLENTY more room in it. Unfortunatly my bag is a hard sided bag with heavy duty rollers, and weights around 15-20lbs all on it's own. My wife's checked bag is more like a big duffle bag that has rollers attached and doesn't weight hardly anything at all. We can stuff more crud in there, but it's not hard sided, so there is more risk of breakage.
The real kicker, is that we are taking a LOT less stuff with us then our trip to Maui last year (same bags) and it seems as though we got more stuff that bag last year. The only differance this year is a 3mil full suit instead of just a 3mil shorty, but it doesn't weight that much!
I'm thinking about moving all the battiers from the hard side case to the duffle style one. Maybe it's just a matter of packing them over and over again until I get it right?