i recently was given a board in texas by a friend to take back home to hawaii...i went to office max and bought 4 big rolls of bubble wrap (that plastic sheet where you can pop the bubbles) and wrapped the ever-loving snot out of my board, then wrapped it with a whole roll of duct tape. be sure you remove the fins! i then took a red sharpie and wrote "FRAGILE" about 100x all over the bubble wrap. sweated a bit on the plane, but when i got her on the other side she was a-ok.
other option is to mail it via fed-ex/ups, insure it for a grand, and if it breaks you got yourself a new board (or two)