Dont take luggage for clothes (ie suitcases) ; put the bare min of clothing (so, 2 pairs of undies) into your boardbag. Rather than taking one heavy bag, try to share the weight equally between a few smaller bags such as board bag, quiver bag, boom bag, or carry your boom on its own (wrapped in a bit of bubble wrap if you like) ...carry the mast on it's own (can you get away with just one mast?) ...you MAY get lucky if you have the weight shared over a few items and nothing is too close to the limit. I've taken 40kg of gear for free when the limit was 20!

Put any small heavy items (extensions, mastfoot, nuts n bolts, fins, heroin etc) in your carry-on and don't have it with you when you check in; have a friend in the waiting area hold it until you've checked the bags in. Tell them you don't have any carry-on, except for the small bumbag you'll be wearing. This will shave a few kilos off the total and win you some sympathy and/or coolness points. You're a serious athlete, not a spoiled shopaholic fool or a druggie backpacker or something.

(Actually, I've never flown with fins in the carry-on, but they're not on the banned list so they could be ok, unless they are very weapon-like...please try it and let us know)

Good luck, post photos!

Build a nose and tail protector out of corrogated cardboard and wrap the board in bubble-wrap, then put it in your well-padded board bag - I wouldn;t gamble on a few clothes. Baggage handlers can be a rough lot.

here my 5 cents based on experience flying various airlines with large amount of excess luggage criss cross around this planet.

1) First rule!!! Don't just hope everything will be fine. Rule of thumb is it won't be. At best you'll get charged a truck load of money at worst they won't take your gear.

2) Always find out ahead of time:
- if the airline takes surf/ windsurf boards at all (Jet star doesn't, British Airways doesn't)
- if the airline includes surf/ windsurf boards in the normal baggage allowance
- if there is a special rate for surf/ windsurf boards

3) Remember there is a 32 kg maximum weight per bag due to OH&S issues. Especially in the US they take this very serious.

4) The usual fare rule between Australian and the lower 48 US states gives you an allowance of 2 bags of up-to 32 kgs each. That is based on international transport agreements. However, as of late some airline (ie. Qantas) have started to only honor this for business class passengers (and Qantas Club members). Cattle class is a whole different story.

5) Once you are in the continental US the 2x32kgs allowance doesn't apply. The airlines pretty much make their own rules as they see fit. So call ahead do avoid problems.

6) RE carry on items. Be very careful with what you try to take on board. If you manage to get an extension on board in the carry on you are very very lucky. I regularly travel for photo shoots and always have to check in tripods as well as mono pods as they are considered a potential weapon. Even more, on a recent flight from Perth a mate had one of those tiny surf board fin alan keys on his keyring... guess what, security made him dump it.

7) Insurance: Most airlines make you now sign a statement that they will not be liable for any damages. To my knowledge there is no insurance that covers windsurf equipment. There are specialist photo gear insurances that cover equipment even if send as checked luggage. Needless to say this insurance is very expensive... approx 5-10% of equipment value per annum.

You best insurance is: Make sure you invest in a good board bag. Don't overload the bag. Make sure the bag is tagged top load only and fragile (although I sometimes thinks that attracts extra abuse).

One last thing about trying to cheat the carry on system by keeping your bag with a friend... most airlines now do another check at the gate before you get on the plane. Especially on international long haul flights.

There are a number of posts in this forum with more info about flying with windsurf baggage. Do a search on it.

here some of my stories:

Germany -> London -> Sydney return with BA around '95:
flight out Australia was fine, was charged a flat rate of AU$300 for a double board bag, no weight limit (this was before the 32kg limit was introduced);
on the way why back I reconfirmed the flight in Sydney and was told that BA no longer takes windsurf gear to Europe on a flat rate, argued a lot but to no avail. They said they will take it at AU$72 per kg for every kg over 20kg... total weight was 72kgs... decided to ship via air freight instead which ended up costing AU$1000,-

Germany -> Canada -> Germany:
Flight out only had a sail bag which I had confirmed in writing at Can$50 flat rate. Just as well as when I got to the airport they wanted to charge me Can$650.
On the way back, 9 months later, I had a double board bag with about 100 kgs (ahh... those were the days). After check in I was told "here is your boarding pass... pay excess over there"... my English at the time was a bit sketchy and assumed they meant over there in Toronto were my stop over was... at the gate I was told off because I hadn't paid my excess baggage... a long argument erupted. In the end I said, I brought a sail bag, I am taking a sail bag, I am only paying for the sail bag... Can$50 I was on the plane. all because I had everything in writing.

Germany -> Fuerteventura -> Germany:
Got one of those cheap AU$150 return tickets on a charter plane. First person to check in... had everything packed into a single board bag... sails, cloths, 1 board etc.... check in chick: "Sorry, we don't take windsurf boards."
My reply: "ahm... I don't have another bag to re-pack."
Check-in chick: "your problem..."
My reply: "can I talk to the manager?"
Check-in chick: "I am the manager..."
Pilot happens to drop in at check-in counter (only seems to happen with charter airlines). I play dumb and ask him why I can't take a windsurf board and explain my delima... he goes to check-in chick: "Just check it in..."
Check-in chick: "But we don't take windsurf boards."
Pilot's reply: "I am flying the plane. I say was goes on and what doesn't. End of story."
Total cost: AU$ 0.

Germany -> LA -> Maui -> Sydney
Germany -> LA: 46 kgs in one sail bag... no problem
LA -> Maui: 32 kg limit was introduced, massive arguments erupt at the airport. in the end they take but stamp my ticket as late check-in. Nearly miss plane... get abused by flight attendant at door... find cock-roach in salad... lose the plot and ask purser WTF is going on. Purser apologizes about the whole situation... brings me a business class meal (tried to upgrade me but business class was full) and bottle of champagne as well as $200 voucher as it becomes apparent that my bags didn't make it on the plane. Plus they will deliver my bag to our rental house in Maui at no additional cost...
Maui -> Sydney: same 46kg sail bag, chick at check-in asks me how the windsurfing was, checks bags through to Sydney at no additional cost or arguments.

and the list of stories goes on... ever since though I always ask about price before hand and get everything in writing if possible and if the airline doesn't have a published policy (most fortunately do now). Also always try and stay below the 32 kgs as airlines will not budge on that one.

wow stehsegler uv done some travelling, cheers for the heads up looks like im going 2 have 2 do my research. just don't want 2 have 2 end up half way home and getting charged an excess if i take it.

lol not after i just got the travell agent quote 2day. owch