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Click Here to read the TSA rules on flying with firearms.
This is the minimum you have to comply with^*. Airlines are free to add and embellish with their own rules, opinions and variable enforcement. In general however, they are not far different from the TSA requirements.

If you fly internationally on a non-US carrier there are a lot more rules and regulations-- some airlines require you to pre-inform them as many as several weeks in advance that you are carrying firearms and reassure them you have all the proper permits. Some international airlines do not accept firearms at check-in unless you have already notified them. Some countries, airlines and airports have difficult, bizarre and/or costly transfer processes.

* LEOs and the like have a whole different set of rules. If they apply to you, you'll know. If not, do not accept the ticket agent's offer of letting you carry your guns on with you, no matter how tempting.

Here's a start at some FAQ's as well:

Q: What's the limit on ammo I can bring on a plane?
A: Outside the US, the IATA sets the rules at 5 kg, which equals roughly 11 lbs per passenger.
Inside the US, the airlines set the rules themselves. Most US airlines use the IATA amount.

Noted exceptions are Alaska Air and Horizon, which at last check allowed 50 lbs. At one time Continental allowed 11 lbs per firearm but not anymore. As always, check first.

In some (rare) cases, airlines can change or waive the limits if you ask in advance.

Note that the packaging requirements do not list plastic boxes as acceptable. Some airlines may allow them, some may not. Sometimes it depends who is reading the regulations that day. I pack ammo in well-taped factory boxes. Some South American airlines have been known to only allow ammunition packaged in metal boxes. As usual, check with the airline first.

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Q: Should I put a 'TSA lock' on my gun case? The kind they have a special key for and tell me to use on luggage?
A: No. Use a regular padlock that only you have the key or combination to. You can (and probably should) put a TSA lock on the outer luggage if you put your gun case inside some other luggage.

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Q: Do I put the 'Firearms Declaration' card the ticket agent gave me inside the gun case?
A: Technically the law says the card should go inside the case. In reality TSA now asks you to put it on the outside of the gun case if the case is inside other luggage. If they do open your luggage for inspection and don't see the card, they'll have to try and find you to open the case and show it to them. If they can't find you... they may pull your guns off the flight.

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Here's a list of previous flying-with-guns threads. Feel free to add additional questions/answers here.
(policies and procedures have changed over the years and what you read in older threads may not be correct anymore)

http://www.brianenos...?...opic=76697&
http://www.brianenos...?...opic=72923&
http://www.brianenos...?...opic=66173&
http://www.brianenos...?...opic=54368&
http://www.brianenos...?...opic=53215&
http://www.brianenos...?...opic=53168&
http://www.brianenos...?...opic=44912&
http://www.brianenos...?...opic=38391&
http://www.brianenos...?...opic=27033&
http://www.brianenos...?...opic=31369&
http://www.brianenos...?...opic=20850&
http://www.brianenos...?...topic=4366&
http://www.brianenos...?...opic=14308&
http://www.brianenos...?...opic=10357&
http://www.brianenos...?...topic=4386&
http://www.brianenos...?...topic=2685&