Haven't heard from E yet if everything got there in one piece.. but we did have success at the check in counter.. no charges and just a few moments of angst.
It was hilarious to watch the reactions as we walked up to the airline check in.. I noticed the TSA agent leaning way over the counter , scrutinizing the cart overloaded with boxes. Pulled up to an available Sun Country airlines agent, she is already raising eyebrows and wrinkling her nose.

Stopped her right away "life sustaining medical supplies".
E was tired, he had dialyzed that morning and also late the night before.. I think he took off too much fluid and felt a little washed out.
I took over and decided to be the "B" to politely and firmly tell the agents that :
1. Yes it was all for one person "oh, uhh let me check with..."
2. It didn't matter how much it weighs, no weight limit for medical devices.
"uhh I will have to check with someone..." (weighed in at 100.5, they let the matter drop)
3. Asked him to sign something.. DH stopped and asked.. "what is it?"
Teeny tiny print "waiver of liability" ... we both said "NO".
Pulled out an article that cites the disability FAA code that states liability limits do not apply for medical devices.
"uhh, I have to check with someone... "
Success! Six boxes of fluid , one 100 pound machine, one box of supplies and an IV pole later... Just one charge for his bag of clothing ($15).
This time he was flying out of the smaller terminal, they only have three budget airlines (Sun Country, Southwest, Airtran) and charter flights . I'm sure they have never come across anything like a dialysis machine before.
His last flight was thru Frontier in the main terminal, it's always busy and security/TSA is super efficient.. thousands of people per hour through the 3 checkpoints. Agents there had no concerns and told him "we're going to believe that you need all of this.. why would someone lie about needing dialysis? " Very true, why would someone lie and go through the hassle of packing that many bags and boxes? And admit they had a life limiting disease
I feel smug and satisfied... petty of me I know.
His principal siddled up next to me during the process.. "How's it going? Need any help?" and gave an eye roll nudge nudge

Naw... we got it under control.

I like her! I knew she would be the type to politely, firmly and throw a little extra "I'm boss here" attitude if needed.
E is in good hands
