Hi Ken,
I don't know if my answer will help you any because right now most of my comercial air flying is done overseas, London, Frankfurt, Rome, Crete, and other locations throught Europe and the Middle East.
However, I have been through Dulles and Hartford International a couple of times since the big change and I always carry a PSK in a Steven Covey Day planner. I have one kit in a Velamints tin that has mostly first aid gear but I also have my spare batteries for my Surefire 6P. I have my fishing kit in a little Altoids strips container. I carry my Weber diamond knife sharpener in a pen holder, supper glue, chapstick and Dramamine with tweezers in a Starbucks Chewing gum tin, a Nalgene note pad and pen, a small American flag, properly folded, a Jewlers ScrewDriver with 3 enclosed "tips", moleskin in gerbers baby formula bag, folding can opener, Starflash signaling mirror, and other assorted items. And I have never had any real problems.
The most throughly my stuff was checked was one time in the Catania Aiport in Sicily and the way that I survived that situation was I make sure that I always start of with a generous showing of my family pictures and the like. I am not trying to get away with anything except my time and comfort and it never hurts to show at the beginning of any search that you are one of the good guys.
One of the best ways that I have found to get through airport security when I am traveling is to ensure that you always arrive early and then there is no pressure o you. No pressure no stress and you are much calmer during any type of security check and that equals less hassles.
I hope that you have blessed day traveling in the states and my guys do too. Laurin