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I've flown a few times with my .45. I put a padlock on the plastic case the gun came in and threw a box of ammo in the suitcase seperate from the plastic gun case. I did wrap the cardboard box in some clear packing tape to make it hold up a little better.

I was on the way to Little Rock on SWA. I got to the counter, asked for and filled out the declaration form and the lady said put the card in the suitcase. I asked if whe wanted it in the gun case. She said no, just in the suitcase. She never looked at the gun case or the gun.

Different story on the way back. The lady checking had me open the suitcase, open the gun case and look at the chamber. Put the card in with the gun and closed up, locked the gun case and got on the plane.

Not much hassle, just different styles.