Riceball -- the issue I'm up against is I'm specifically trying *not* to check luggage at all. I checked a good sized (second largest in my set) suitcase last year because of costuming props, and really did not like having to lug it around Atlanta, on MARTA and then through the hotel. So I'm packing much much lighter this year, just one rollybag that will fit in the overhead compartment. And as far as I know, every airline except Southwest has checked bag fees now, and Delta is the only one that has the non-stop overnight flight I was looking for (and have already booked), so I'm stuck with fees if I want to check anything. With the exception of any sort of weapons for Hit Girl, all my costumes will fit in a carry on bag, so I'm to going to try to stick with that.
So yeah, checked luggage is really not an option -- I'm more likely to forgo the staff completely than check a bag. But if I plan well, I think I'll be able to fit the whole thing, in pieces, into one of the standard sized USPS boxes for instance. I was hoping to be able to take it in my one small carry-on bag, but the TSA's regulations being what they are, I definitely won't be able to get the foam blades through, and probably not the pvc handles either, as they're probably too club-like.