I was one of the baggage handlers. I have checked in thousands of firearms.
Step 1. Make sure the firearm is unloaded and that there is NO ammunition in the hard sided case or the larger bag that it is inside of.
Depends upon airline policy. There are no Federal regulations against having ammunition in the same hard sided case with gun, or in the same luggage with the gun case. The airlines I typically fly on allow the ammunition to be locked in the same case as the gun itself.
http://www.ecfr.gov/cgi-bin/text-id...aa19b62b2f7&node=49:9.1.3.5.9.2.10.6&rgn=div8
49 CFR 1540.11:
"(d) Ammunition. This section does not prohibit the carriage of ammunition in checked baggage or in the same container as a firearm. Title 49 CFR part 175 provides additional requirements governing carriage of ammunition on aircraft."
Step 2. Declare it at the ticket counter, show it is unloaded ( they should never touch your gun),
There is no Federal requirement to show that it is unloaded or for the airline to verify. If they want to verify it is unloaded, they will ask. Otherwise, showing the gun to someone when not asked to is only asking for trouble.
sign the Orange Declaration, and put that into the hard case.
Again, wrong - unless the hard sided gun case is going by itself. Otherwise the declaration tag goes outside the locked gun case, but inside the luggage the gun case is being transported in. That way TSA can verify the declaration tag is properly signed without having to unlock the gun case.
Step 3. Lock the case with a GOOD lock ( not a TSA lock) , also lock the larger bag.
Just for clarification, the luggage containing the gun case either gets locked with a TSA lock, or unlocked. If the luggage containing the gun case is locked with a standard lock, TSA will be more than happy to include the broken pieces of the lock inside the luggage with their inspection notice.
Airlines will only let you check in 11 pounds of ammo in your other bag. I have never figured out where that number came from.
http://safetravel.dot.gov/index_ammunition.html
"US DOT regulations do not limit the total number of packages or the total weight that may be transported in checked baggage; however, the ammunition must be for "personal use." Many air carriers limit the amount of small arms ammunition that may be carried in checked baggage to 11 lbs., (5 kg) consistent with international standards. When in doubt, check with your air carrier."
Just PM me if you have any questions.
It would probably be a better idea to read the Federal regulations and written airline poicies rather than asking someone's opinion, which may or may not be the same as the written facts.