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@tmevans
just thought this was worth a mention. we put our tandem on a ryanair flight a couple of weeks ago and learnt some things. The
plan was to slot two boxes together. By accident we got boxes for an L and XL bikes from the same brand ridgeback and it seemed that the Xl box was slightly bigger. Either way the L slotted into the XL perfectly. I glued them with pva then taped with two and a half rolls of duct tape. We were unlucky in that we were sent from one place to another in the airport and where we ended up they insisted on opening the box and cut through all the tape to do so. The ladies at the x-ray machine where we had been then came to intervene saying that they could have fitted the box through their machine so this could have been avoided. Anyway it all worked out in the end. Doing it again I would repeat everything but really insist to be put through the x-ray machine to avoid the horror of watching while the bike was partially unpacked.