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Here's my procedure:

1. Place the unloaded gun and magazines in a pelican case with my name and cell phone on a tag attached to the case. Make a note of model and serial number (just in case you need it for some reason).

2. Padlock in both places for the case (do not use a TSA approved lock). Keep the key with you at all times. You may need it during an inspection.

3. Case goes in suitcase.

4. Place ammo in a factory box (this is a requirement at American Airlines - they have asked me about the ammo in the past).

5. Put the ammo in the suitcase.

6. Put a TSA approved lock (i.e one they can open) on the suitcase

7. Declare it at the counter ("I have an UNLOADED firearm to declare" is my exact words). You'll have to sign a card. Ask the clerk where to put the card (in with the gun, or just in the suitcase - it varies from airport to airport)

From there the process varies from airport to airport. D/FW will make you take the case to a particular TSA station for inspection and sometimes they want you to open the gun case, Las Vegas just takes the bag and puts in the conveyer.

When I get to my destination and claim the bag, I immediately open the bag and ensure the gun case is still there. If it weren't I would contact the airline baggage people and insist on both law enforcement and TSA be present for reporting a stolen firearm. If they don't want to contact law enforcement, I would pick up the phone and dial 911 to report a firearm has been stolen from the secure area of either your departing or arriving airport.

I've done this about a dozen times and have never had an issue.