Just wondering if anyone had any experience of check-in the buggy on any flights? I may consider flying instead of driving half way through the country.

For my buggy, I could disassamble it into small pieces except the axile...so maybe I have to pack the axile in special oversized bag? I would love to know if any of you have done this before.

done it many times, it all comes down to your weight allowance and distributing the parts into bags to get the weight what you are allowed otherwise you pay for excess weight. All airlines are a little different as to how picky they are and it often comes down to being nice with the check in person how much they will allow without charging extra.
I now usually take a heavy duty snowboard bag and it fits a 150cm axle and the side rails easily with room to roll kites in between the rails and axle and some other things and then I'll put straps around all the bits to cinch it tightly together so it won't rattle around during handling. Cover any tube ends with tennis balls and any corners with foam - these parts are often what can puncture the side of a bag so minimize pressure points.
The tires add quite a bit of weight so going to events like NABX I'll just take hubs and get the tires there and make sure I ride hard to burn them out before coming home so I'm not bringing extra weight back.

You can also explore shipping your buggy ahead of time by ground so it'll be there when you arrive.

Thanks for the tips Mark. Sounds like heavy duty snowboard bag is the ticket then. I don't want to ship them as I may still want to use them before I leave =].

I turned up at the airport with my 75Kg buggy in 5 bags for the 10.5hr flight to Ivan. Yes, 75Kg bug.

One of my jobs is working at an airport car park and shuttle ride company. I used their luggage weighing scales and juggled the weight around from bag to bag until all but one bag were under 22Kg allowance as markite said.

One bag weighed in at 32Kg and there was no getting around that.

I prepaid online as it was cheaper. I also paid for one extra bag I didn't need because I forgot to allow for the fact that the first bag goes free as long as it's under the weight allowance. In total I paid around £530.oo for 5 bags for a total of 100Kgs. It would have been more like £400 or $600 USD if I hadn't paid for the extra I did not need. That's the cost for both ways.

So in total I used 5 large pieces of luggage + a hiking rucksack that went on as hand luggage. I think you're allowed 9Kg in the hand luggage but they don't like you loading it up with 20mm nuts and bolts.
In the end they just waved me through.

2x 150L Gul bags, 1x large snowboarding bag for the frame and axle, 2x cycle wheel bags and a small hiking rucksack for the camera gear and paperwork.

My advice is to keep everything as light as possible. Not so much to keep the costs down but for yourself. Lugging it around the airports and loading the hire car is a pain in the ass.

The mistake I made was using GSX 400 wheels with motorbike tyres. In total, all three wheels weighed in at a massive 36Kgs!! Lanseggers for me next time and I'll bury the buggy in the dirt under the cover of night when I'm finished.

Keep it light. Maybe arrange to buy wheels when you arrive and sell 'em on cheap when you're done.

that is a good point about paying for an extra bag. The last time Ziggy and I flew to with one airline it was a flat rate of 50.00 for an extra checked bag and that was cheaper than paying the per kg/lb fee on the same amount of weight if it was excess on the other bags. This allowed us to bring more and split the cost between us.