Pelican is the way to go. Buy once, cry once... A good 2nd hand deal comes up on here every couple of months. Airline baggage limit is generally 23kg, I've had several rifles in my pelican case and it did not go over the limit.
The best thing you can do for the cheaper plastic cases is to upgrade the internal foam to a very high density version.
Para Rubber is where I normally get the spare foam.
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