Hey Dave,

Here's what I've learned over the past few years of shipping jets -

1. You get billed by dimensional weight, so go ahead and make the crate super strong - less likely to get damaged and doesn't add to the cost of shipping.
2. Hire a professional crate builder (if you can find one local). I found one and he's amazingly reasonable, can slam 1 together in a few hours and has everything necessary to make it right, and understands loads/trucks/forklifts/etc. You'll have a re-usable crate that can be grabbed by a forklift and should have handles as well.
3. Cushion your models in foam! Can't stress this enough. Solid mounted planes end up with loose formers from my experience!
4. Truck freight is rough, but reasonable, usually 3-5 day delivery is what you'd want to afford to travel cross country. Air is rediculous.
5. Insurance - if its a "used" model, their is a flat rate and they will not go above this - double check with your carrier.
6. Pre-arrange the return! Have waybills with you and a pickup scheduled, makes life easier.

Here are some photos of the crates I've used to ship with, all basically the same, foam center strip down the bottom (Cougar crate has it on each side to cradle the fuse), wings in bags secured against the sides of the crates, stab strapped to foam under the top cross brace, so my crates are all stackable, cause even with DO NOT STACK on them, they will still do it.

I buy the strapping material and plastic clamp-locks (like some use on suitcases) at Ace Hardware, so I can easily sinch down the fuse in 2 spots and the wings as well.

I've started to make internal braces now with certain crates to carry my toolbox and air compressor so I know I have what I need.