I just got back from a week in WY where I took my carry weapon with me.
Here is my experiences at the two airports where I checked the weapon...
1) How much of a hassle you experience checking the firearm will depend on who checks you, how much they know of the rules, and (to an extent) how they view firearms.
2) Yes it is a hassle to some degree, and will take at least an extra 15-30 mins, but if you like to be armed, then its worth it.
3) Know the rules yourself for the particular airline you are flying on.
4) When you go to to the checkout counter, declare that you have a firearm. They will then ask a few questions such as "is it unloaded?", "is it in a locked container?", ect. They will not touch the firearm nor do they have to see it. You will then fill out a orange card declaring that it is unloaded which you will put either inside or taped to the outside of your locked case. Flying from Houston, they had me put it inside...flying from Jackson Hole, they had me tape it to the outside...(apparently, you tape it to the outside when the firearms case is inside of another bag )
5) They will then have a TSA agent (who probably knows nothing about firearms) inspect your bag for (I'm assuming) explosives whether they do it there in front of you or in the back before they put it on the plane....In the Houston airport, the former burger flipper TSA agents WILL take their time and act like you are not even there. Flying from Jackson Hole, WY was a MUCH better experience.
6) TSA locks are NOT mandatory, and I would advise against them. I know I don't want someone finger-fugging my weapon when I'm not around. I would use a very well made keyed lock. I wouldn't recommend a combo lock since I have seen videos of how easy it is to unlock them. (And no I'm not talking about someone pulling "Italian Job" and using a stethoscope!)
7) Lock BOTH SIDES of the hard sided case, even a Pelican case can be pried on one end to some degree without a lock
Overall, I think the hassle is worth it to have your carry weapon with you, but just make sure you're there early. Hopefully this, along with what Jason wrote, will help prepare anyone who hasn't gone through this yet.
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