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Anyone ever made a tuba flight case similar to the unitec tuba cases (made out of plywood). If so, any pictures, any advice?

I once made a big plywood box for shipping my Piggy. It was just under the maximum size for airlines--I called 7 or 8 and got the dimensions, made it to the smallest maximum. It had lots of padding, a couple of belts to hold the horn in place, more padding, and wheels. It was heavy, also. It did the job, even survived being turned upside down after the dingbats put it ON THE WHEELS on the conveyor. This after being assured at every point of that trip that it would be wheeled to the cargo door specially. It wasn't difficult, but it was 28 years ago. Things have changed dramatically. You'd be best off buying a seat for the horn in a gig bag, frankly.

Airlines do not accept sharp-cornered crates, even when accompanying deploying military units. Buy a Walt Johnson or similar case.

bloke wrote:- packing the tubas-in-gig-bags in solid (NON recycled materials) corrugated cardboard cartons, stuffing the cartons with inflated "packing pillows", and utilizing light-gauge collapsible dollies.

Somehow, I still believe that there would be less likelihood of bell creases with the cardboard cartons and packing pillows.

Serious question:
What about when the TSA cuts open the box to inspect, and does not properly repack it?
Of the few times I have flown with tuba (kolledge reasons;) once the "accessory" compartment door was not closed and latched after an inspection. A small screwdriver for tightening the rotary valve linkage had fun bouncing around inside the case and scratching up the tuba during the flight.
Lesson learned: put nothing in the case except the tuba (and padding).