Thanks for an interesting topic! My post 9/11 travel has been limited but I had gone the other way regarding air travel - eliminated my carry-on luggage and checked everything I could, simply accepting the additional hassle and delay (and loss of access to penknives, etc.). Your way definitely looks better!

Some questions:
The vest that you've presumably got packed with stuff - do you take it off at the security station and run it through the x-ray belt, or do you walk through with it? Has it caused any delay there (hand searching, etc.)?

What carry on bag do you have (or recommend)? When you say to get one that you can sit on, do you mean just a good sturdy one or specifically a hard-sided one?

Thanks to all for the great posts!

- Cliff