In the past they would normally just put the prototype guts into an old body shell but if they don't fit then they need to go to plan b.
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I fly about four times a month, many airlines have started to actually weigh hand luggage in the hope it is too heavy and you have to pay to check it. Which airline are you using?
Avoid, Southwest, Spirit, AirTran and AA from many destinations, plus any of the multitude of "budget" airlines, total ticket price to actually travel is often way above regular scheduled airlines.