Direct from the TSA website:
The big thing to note in that popup window is that the blade(s) MUST be securely wrapped or sheathed to avoid injury to TSA employees. What it DOESN'T mention, is what will happen when a rifle case like mine, below, is encountered by a Geeky TSA employee, full near-to-bursting with toys, and the employee decides that this warrants a "VERY thorough inspection".
Granted, that's not giving the TSA folks much credit, but there IS a possibility of it happening, and here's what I do to avoid it.
I print out the screenshot above of the official TSA stance on swords, and place that on top of EVERYTHING inside my gun case, where it's impossible to miss. This helps avoid unwarranted confiscation. Then, with brightly colored (typically red) plastic zip-ties, I secure my sword in its scabbard in a ren-faire fashion, so that it cannot be drawn without obvious intent, including cutting the zip tie. Next, I type out a VERY POLITE, but informative note, and masking tape it to the throat of my sword scabbard:
What this note does, essentially, is warn the employee of their peril, without putting it in such a context and, simultaneously, remove the possibility of lawsuit, since they were fairly informed prior to making a stupid move and hurting themselves. Instead, they are confronted with the question of "Do I really want to start cutting this dude's luggage open, or will the x-ray suffice?" The viewing equipment they possess is plenty sufficient to see that there isn't any circuitry attached to explosives inside my scabbard, and that my note speaks the truth plainly.This sword is SHARP. It is a functioning historically-minded piece used for reenactment purposes. If further inspection is required, you may cut the [color] zip ties securing it, but please use extreme caution.
A few years ago, flying down to LA to hike with Ernildhir, I went through security after checking my baggage, got to my gate, and got comfortable to read for an hour before my flight boarded. Ten minutes later, my name comes over the intercom, paging me ALL THE WAY BACK TO THE SOUTHWEST DESK at the front of the airport.
They wanted me to unlock my sword case.
Then, naturally, I had the pleasure, of going BACK THROUGH SECURITY. AGAIN. Didn't miss my flight, but I wasn't too thrilled, either.
The solution to this problem I've found, is to make yourself present at the inspection of your gear. Now, I arrive plenty early (as you should anyway), and when I check the baggage and they ask the obligatory "Is there a firearm in that?", I politely say "No, but it is locked. Would the TSA inspectors like to meet me at the door so I can unlock it for them, and then secure it after their inspection?"
This isn't asking too much, because it's exactly what wound up happening that first time. They had me unlock it, took it behind the door for 5 minutes, and then closed the case and opened the door again, for me to re-attach the lock. Now, when this happens, I'm ready and waiting with four fresh zip-ties to secure the case all the way along its open edge, where there are multiple padlock loops. The handle is padlocked, and the rest is secured firmly for the duration of the trip, so if there's been any tampering, I'm instantly aware of it.
Anyone else have Airport horror stories/advice?