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Shipped mine in a cardboard bike box.
You have to turn the handlbars and remove the pedals, and you ABSOLUTELY need to keep a copy of the airline's official bike shipping policy with you. 99% of airline employees won't know the policy, and I guarantee you, some officious jackass is going to cause trouble for you if you don't have documentation.
Cardboard is easily punctured, of course. If the bike you're shipping is VERY valuable and a scratch would break your heart, get a hard shell.
Cardboard box secret
All cardboard bike shipping boxes are not created equal.
Most are pretty cheesy, low cost, one-piece Chinese made boxes.
A few, which the higher-end bikes are shipped from the manu are actually pretty good. Trek, for one, ships their Madones in a very HQ two-piece box that would suffice for what you want to do. Get em for free at my LBS....
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