When taking my personal camcorder....
I tend to pack my clothes and my dive gear (sans reg) into a large Kona roller. 2nd bag is a pelican case thats has extra room for misc in it besides the housing and lights. I can usually get both bags in under 50lbs. I never take weights with me, its actually cheaper to just buy new ones if I have to, although I try to rent. I have a smaller carry on with the actual camera in it and a backpack with my laptop.
When I'm taking the Red for a job...
I buy a second airline ticket. One carry on for the Red body, One carry on for the lenses. Check bags will have the housing, sometimes another for sticks, another for a head, an accessory case, and a personal suitcase/dive bag. I learned a long time ago that frequently its cheaper to buy another ticket then to pay $250/flight to cover extra bags, plus you get so much extra room and who really cares about the check in people thinking your crazy.
For a really big jobs, I'll ship out the gear via Rockit Cargo. They directly handle it and its insured so I don't mind sending gear anywhere in the world with them. A few times I've hired a PA or two just to deliver gear (and will be doing that next week to send some stuff to Nola from NY). They fly with some of it and I fly with some it, sometimes on different flights because I'll get them the cheapest flight I can. They're paid to wait. I'll take whichever flight I have to.
Another thing is that every now and then the airlines will run a promotion (they frequently won't tell you) where certain types of luggage is free. I've had a flight on jetblue from NY to Florida where surfboards were free (normally the oversize would run $50 each way). Twice so far I've found a promo where Dive gear was free. Sometimes you just need to call the airline and ask.
~Marque