I carry my gear on commercial airplanes in a Lightware multiformat MF1420 case 
(22/16/8). It's fabric, so it doesn't look heavy, even though it may be filled 
with 20+ lbs of equipment. It fits without any problems in American Airlines 
and Quantas carry-on sizers. I usually stuff it with an EOS body, 70-200mm, a 
medium format body, and 3 other lenses + filters/lightmeter. 

I pack the backpack in my suitcase, and re-arrange the gear when I get to my 
destination. 

If you don't make a big deal of having camera equipment in it, and you don't 
make it obvious that it's over 10lbs or so, the person at the ticket counter is 
unlikely to make you weigh it. For safety, put it under the seat in front of 
you, not in an overhead bin.

Keep zip-ties with you on hand just in case they do make you check it, so that 
you can secure the zippers to prevent the bag from accidently opening during 
transport. It hasn't happened to me yet, but it could, so you need to be 
prepared. If the flight is full, airline personnel will sometimes ask you, as 
you are boarding, to check large pieces of carry-on at the gate.  When you get 
off the plane, they give it back to you at the gate... no baggage handlers 
involved. :-)

-Roger  

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