Hi Mac, great post. I've flown with firearms without the regs printed and everyone was friendly and co-operative. Even in California of all places! Nobody has ever asked me to open the bag and inspect however. It was declare, sign and I was on my way.
Also, I have to toot my own horn here. I own a submachinegun and it is rather tough to travel with submachineguns as there are a lack of TSA legal hard cases for them. One of my new product lines features a hard case with custom cut foam. If you are a frequent flyer with firearm - this might interest you.
Here's my case.
I'm going to be doing them custom - you can have your gun, slots for mags, two guns, cutouts for ammo boxes, etc - all in hard foam cut on an CNC router.