I'm another Pelican 1510 user:
Pelican 1510 Carry-On:
- Remove all the foam and dividers!!!!
- 3/2 Wetsuit on the bottom
- Ikelite enclosure for Canon 5D towards the handle end, enclosure filled will gears, orings, etc
- Regulator coiled up on other end (hog-style long hose, short hose)
- Wrist dive computer and compass wrapped in cloth and stuffed inside the 8" dome
- 8" dome with longest port extension tube placed on top of reg (port tube fits inside coiled up reg)
- Strobe cable and arm
- Batteries, chargers, small flash lights, etc stuff around edges
- Dive boots above the dome port (boots are heavy!)
- Small cable lock used to lock this same case to a pipe or bedframe in the room (if needed)
- Swim trunks a very light tee-shirt on very top.
- The case is quite heavy.
- I always have a large padlock on it. Everytime it goes through security they have me unlock it (never cut)
Think Tank (Medium Sized Forgot Name) as the camera / computer bag.
- Camera Body
- Canon 100macro, 17-40, 40 Pancake and the Rokinon 14mm.
- Ike DS51 strobe
- USB powered 500gb portable drive
- Card reader and USB hub
- Surface RT (web, movies, email, transfer files from cards to drive, preview 5d2 video)
- Filters (polarizer, ND)
- Camera strap
- Ballhead (tripod goes in checked baggage - only for land shots and video)
Large Roller Suitcase (checked)
- Large Dive Bag (w/tags) And everything else inside (in case suitcase breaks)
- Housing handle
This has worked for all the common Caribbean destinations and rarely have I paid any luggage fees since I'm only checking one item. Since we usually fly Delta (Minneapolis) the first bag has no fee for all Caribbean and places like Bonaire and Belize are two checked bags without fees. For the small hops (Aruba to Bonaire, Belize City to Ambergris Caye) the Pelican goes underneath but the camera backpack is okay to carry on.
I can't wait to go to the Pacific - yet I know this travel setup would easily exceed the carry on weight limits as the Pelican 1510 loaded probably weights over 45lbs with all the gear.
I really appreciate this thread as it has a great deal of useful information for traveling lighter and awareness of the various carry-on weight limits which haven't been a problem - yet - for US based carriers.