I'm sticking with the big aluminum box. Its the only thing I feel safe shipping. I've had wooden boxes that have been damaged, and I've seen gun cases dissapear so I wouldn't recommend those. I've used cardboard like Randy, and it does work pretty good. I prefer it over wood, thats for sure. Just get double wall cardboard quite a bit bigger than the size you really need and have the planes float in the center sorrounded by popcorn and foam. Leaves a nice mess in the hotel room.

Personally, I think the big aluminum boxes are the safest best, but it also costs the most to ship. I ship the aluminum box, and a 2nd box with my tools / flight box / accesories for about $60 - 70 each way (ground), and carry my transmitters / chargers on the plane. Best bet is to find a driver that hauls your stuff