When I had a Mini (stainless), I flew with it in a Samsonite hard suitcase (which I still use for my Micro). I use 2 memory foam dog beds for padding. With the rEvo sandwiched in between, it was held very securely and well padded on ALL sides. Not only front and back, but all around the sides/top/bottom.
With the loop, NERD, and handset removed, the suitcase weighed 49#, ready to fly.
For y'all well-to-do folks that get to fly with 70# allowances, I guess it's no big deal. But, for us peasants with a 50# allowance, that setup was key to my air travel happiness.
I've flown with that suitcase and a rEvo inside to Utila and to Bonaire. And I used the same setup to ship my Mini and, later, my Micro from Virginia to Washington (state) via UPS for service. It has worked perfectly every time and the suitcase itself is still it perfect condition. It wasn't all that expensive, either, purchased at Costco. Dog beds from PetSmart.