I apologize, I should have been more clear on the TSA locks issue on the gun case. It's not a TSA issue, but an airline issue. TSA says on their website:
- The container must be locked.
- The passenger must provide the key or combination to the screener if it is necessary to open the container, and then remain present during screening to take back possession of the key after the container is cleared.
However, Southwest Airlines (which I always use), says on their website:
- The locked container or suitcase must completely secure the firearm from access. Cases or suitcases that can be pulled open with minimal effort do not meet the locked criterion.
- Only the Customer checking the luggage should retain the key or combination to the lock. No exceptions will be made.
When I asked Southwest about "only the customer" aspect, they said that means no TSA locks on the gun case. I just checked American Airlines' website, and they say TSA locks ARE approved. US Air's website has language similar to Southwest's ("Baggage containing firearms must be locked at all times and the key or lock combination retained by the passenger"), but I've not talked to them so I don't know what their position is on TSA locks. In the end, if you're going to use TSA locks, I think it's best to check with the particular airline. Since TSA locks are not required, I use non-TSA locks on the gun case.
Of course, other people's experiences will vary. The counter person has always inspected the case visually, and then asked me to lock up the gun case afterwards (I put the locked gun case in a suitcase that is checked). I've been asked to follow the suitcase to TSA and wait until TSA says I can go. I've also been told that I could not follow the suitcase to TSA, but TSA will call me on the intercom if they need me to open the gun case. I've never been asked by TSA to open the gun case.
Is disassembly necessary? No. The reason I disassemble is, when the case is x-rayed, I think a disassembled gun is more likely to appear safe to a screener (i.e., unloaded, safe condition to fly). It's not necessary, but I'm happy to take that extra step if that helps ensure I can go to the gate and get on the plane without additional hassle.