Info has it that the some of the so called rip-off airlines are too pricey. While I'm not complaining about FedEx their pricing seems a bit high, or is it that everybody ships in small boxes and my mistake was the larger box?
Out of curriousity, which airline will you be flying, and what is there bike charge? You may have saved money. U.S. Air, for example, charges $200 per bike. I believe Delta is $175.
As noted, size can matter. Last year we shipped two bikes UPS in two separate boxes from Philly to Missoula. MY GF's bike is 42cm so it can go in a relatively small box. I used my pretty large CrateWorks plastic box because my bike is 60cm and has correspondingly larger things like bars and stem. Also has 700c wheels vs. her 26". Shipped via a LBS. While the shipping bill was not itemized, it was their belief that my bike was more because of the larger box.
Looking forward to flying Southwest to Cycle Oregon in September.