For all domestic trips involving air travel, we now ship our bikes fedex ground or ups in advance in Trico Iron cases.
Have you looked into Bikeflights.com? I will be using them again for the second time next week. They are essentially a FedEx discount service. You buy on line and they email you the prepaid shipping labels. Their web site even has a drop down menu with the dimensions of popular bike cases.
Shipping 65 lbs. estimated weight of box, bike and rack round trip between Philly and Rapid City, SD. Total with $1,500 of insurance and $5 surcharge for pick up at a LBS in Rapid City is $115 round trip for 4-day shipping. I will be flying Delta, which charges $150 each way.