Pete,

What I have seen done a few times is this: purchase a few sheets of 1/4 4x8 plywood and some 2x2 stock, and use drywall screws to create a box, usually with a full sheet of 4x8 as the top and the bottom, and a ripped down to 2' sheet to make the sides and ends.

The 2x2s make a framework around the perimeter of the top+ bottom and at the end corners. Goes together with drywall screws. Probably only takes 30-40 mins to make. Then the plane is stapped down on some styrofoam and/or urethane foam .. must be strapped pretty tight to keep it from slamming around.

Then ship by truck .. I have gotten planes via YRC (formerly Yellow Freight). Rates are $200-$300 depending on distance, can be insured for full value, a recent shipment from Colorado to my place in MD took about 3 days.

Seems like a great way to go...

Others seem very happy with Greyhound if you can get it to fit in their max size box, and I believe it's a bit cheaper too...

Dave