To be honest, I'm disappointed when they don't check the band in my baseball cap. Most US checkers don't, overseas checkers always do.

I have a Swiss-Tech Micro (http://www.amazon.com/gp/product/B001AY2...HYS0MTR3R4VQDFM) that I've put in the dish for years with my change, flashlight, and other crap. I've had use of the pliers and little screw drivers often enough to make it well worth carrying.

I carry a small pocket-sized notebook and pen, which are very handy for noting things people tell me, getting email and phone numbers, and such. Note my pen:
http://www.flickr.com/photos/civex/5507277599/

When we're traveling, my wife and I take our handheld radios, which we've never had a problem with.

My EDC key chain includes a small quark mini AA flashlight, the smallest folding "knife" you can imagine ( spyderco bug, just a tiny bit more than 1" cutting edge) and the world's worst bottle opener:

It has been dremel'ed out of some mini prybar thingy. Not really useful for opening bottles (I didn't get the shape right), but highly useful as pry-thingy and flat screwdriver.

The thing is, those items has repeatedly and consistently gone through TSA screenings, in U.S and Europe. The first 2 or 3 times it was due to neglect on my behalf (I forgot to put them in checked baggage), after which I really didn't bother. Probably too small and unoffensive to be illegal, I guess. Now if the TSA doesn't worry about them then I don't expect anyone else to give me trouble.

The knife is too small to be useful for anything but the lightest possible cutting duties. I wouldn't want to whittle a fuss stick, but it is good enough for many urban tasks. Such as cutting zip ties or opening those clam-shell style plastic that covers many of today's gadgets when you buy them. The scraper/bottle opener thingy is very good for opening letters, card board boxes and the like.

I have carried the Doug Ritter designed AMK PSK for years through airports, I just pulled the scalpel blade out. I put a wire saw in it instead, and it has never been questioned. I have also built small kits that do not look like survival kits, out of stuff which serves the same function as those items in the PSK, but come from the drug, hardware or department stores. I have in the past carried a flint blade, which made it through, but that no longer works, and I do not recommend trying it. Add a light and something for collecting and purifying water to the PSK, and you have everything you need, minus a good blade. You just have to wait until you get to your checked bags.

A few possibles:
Metal stuff
- Trying to keep this legal, but could you put a wallet card type knife in your billfold and slip the billfold in the coin tray (I don’t travel by plane so no idea if this would even work or what might happen to you if the item is discovered so I certainly am not recommending that anyone try it)
- Victorinox mini-pencil (the one from the SOS kit)
- Carabiners and split rings (of course these could be incorporated into your keychain)
- LED light
Plastic stuff
- In wallet, a gift card wrapped with duct tape AND electrical tape (there is room for both, in fact I think I got the idea for this from another ETS member), Fresnel Lens, and Signal mirror
- Tubing
Wood and Paper
- Cards in wallet with useful info, like knots
- Small block of fatwood
First Aid Stuff
- CPR Shield
- Wound Closure Strips
- Superglue
Other Stuff
- Wear cargo pants, and add a heatsheet blanket and/or bivy to one of the cargo pockets (someone beat me to suggesting a pocket poncho as an alternative)
- Eyeglass repair kit (obvious for me as I wear glasses)
- Water purification tablets (to go with the water bag)
- A length of cordage

Would matches in a watertight PLASTIC case make it through? How about a lighter? I haven’t traveled by plane in over 25 years so I don’t know what the security measures are. Do you empty your pockets completely? If so what gets through and what doesn’t? It seems that from what everyone is saying it is very subjective and somewhat based on the area you travel in.

Has anyone encountered a TSA problem with the dedicated metal "tactical" pens?.... I haven't flown since 9/11 and am planning a trip to San Antonio later this year

I think I've got the right thread posted below, but it appears that TSA has wised up about the "traditionally non-weapon instrument designed as a weapon" bit.

http://edcforums.com/showthread.php/59832-busted-for-a-stinger.

Mark_R...I sent an e-mail to TSA and will post the reply if I get one, on the purpose built pens.. thanks