Overview
Traveling with a drill rifle can be a daunting and intimidating process. There are strict laws and regulations governing the transportation of firearms, and these rules vary from state to state and airline to airline. That’s to say nothing of the fact that airports treat firearms differently, lack uniformity in how they handle things like screening, etc., etc., etc. In this article, we will provide an overview of the process of checking in and flying with a drill rifle in most United States airports.
We promise it’s actually very, very easy but we DO recommend you give yourself additional time (we usually recommend at least an extra hour depending on your comfort level) to make sure this process goes smoothly without your needing to rush!
Step 1: Check Federal and State Laws
Before you travel with a drill rifle, it would be good to familiarize yourself with federal and state laws regarding the transportation of firearms. The Federal Aviation Administration (FAA) regulates the transportation of firearms on commercial flights, and these regulations apply to all airlines that operate in the United States.
Each state has its own laws regarding the possession and transportation of firearms, and these laws can vary significantly. Some states allow open carry of firearms, while others prohibit carrying firearms in certain areas. Therefore, it is essential to research the laws of the states you will be traveling to and through to avoid any legal issues.
While it’s been suggested that attempting to pass your drill rifle along as a prop of some kind is useful, after hundreds of flights to destinations all over the US, we’ve found it easiest just to declare it as a firearm and casually reference its actual use in passing!
Step 3: Pack the Drill Rifle Properly
When packing your drill rifle, it must be secured in a hard-sided, locked case. The case must be sturdy enough to withstand normal baggage handling procedures and must be locked with a TSA-approved lock. 
Any typical hardshell rifle case will do but the key is getting locks that will ensure it cannot be “stretched” open upon hand-inspection. Small TSA locks or double-looping “cord” style locks are ideal solutions! 
We also recommend picking up what’s often referred to as a “rifle sock.” Not only does this cloth bag help prevent rusting (many are teflon-infused), it also serves the added benefit of obscuring your rifle when you have to open the case to declare your firearm!
NOTE: You do NOT need to lock your case en route to the airport; carry your locks in an easily accessible location (such as in the case itself).
Step 4: Declare the Firearm
When you arrive at the airport, you must declare your firearm at the check-in counter. This is as simple as walking up to the counter and stating, “I need to declare a firearm.”
The airline will ask you to complete a declaration form, which will be placed inside the case with your firearm. This is why we recommend you leave the locks OFF your case. The airline will then verify that the firearm is unloaded and properly secured in the case.
We also recommend having the gate agent place the luggage tag around the handles when they are separated and opened so that any subsequent TSA searches do not require the complete removal of the luggage tags. About 50% of the time, we have to remind them that this might be a good idea so it’s helpful to hold the case open as they are preparing the luggage tag.
At this stage, you can lock your rifle case.
Step 5: TSA Screening
After declaring your firearm, you will need to go through TSA screening. The firearm and ammunition must remain in the locked case, and the key or combination must be kept with you at all times. You may be required to open the case for inspection by TSA, but they will not handle the firearm.
This is the stage that can vary wildly from airport to airport. Sometimes, the rifle will be taken from you and transported to TSA screening and you are free to go. Sometimes, you yourself will be physically required to walk to a TSA screening point and drop it off. Sometimes, they’ll tell you your rifle is good to go. Other times, they’ll give some vague instruction like, “Wait about 15 minutes and if it doesn’t come back out, you can go to your gate.”
This is the stage that we recommend leaving time for. It can be entirely normal or it can be very odd.
Step 6: Collecting Your Firearm
After your flight, you will need to collect your firearm at the baggage claim area. Firearms are typically returned to the oversized baggage area, and you may be required to provide identification before collecting your firearm. Sometimes, though not always, firearms are brought directly to the airline baggage office. You’ll likely beat your case down to the baggage claim area so it never hurts to find someone from your airline to ask!