While I don't have a Vader costume, I
do have a Boba Fett costume. Like Vader, it is also a costume that contains lots of different parts. I'm in the 501st and do a number of appearances every year. I decided from the onset to find a solution to toting and storing my gear. This is what I came up with:
A wheeled trunk from (of all places) Bed, Bath, & Beyond. $39.99 (back in 2002):
It's lockable, and I can grab one of the handles and roll it where I need using the built-in wheels on the bottom left side of the trunk. I've taken it to DragonCon, and more events than I can count and my costume has *never* been damaged while inside it. The trunk is made out of wood. The outside is covered in a plastic/vinyl-like textured covering, and the inside is covered with a durable wallpaper-like material. The whole thing has held up extremely well, even after tons of trips.
After buying it and getting it home, I installed a 3/4" thick piece of shelving to divide the interior of the case into 2 compartments - one for my costume, and one for my (MSH) fiberglass helmet. I covered the divider and the interior walls of the "helmet compartment" with eggcrate material. I then mounted Army belt webbing to the inside of the lid to secure my blaster to. I also added a pouch to hold my gloves and other small items that might get lost. My shin tools are mounted inside the lid also, as is a mirror (not pictured) because it's always nice to know if you have your stuff on straight.
I figured since Fett is a "gun for hire", why not make the inside of the case look like a hitman owned it? :lol
I'd love to have a flight case, but the ones I looked at (for the size I needed) were $500-$600 and weighed 75 pounds EMPTY. :confused
This case is $459 + shipping, and is almost exactly the same size as mine. I think I'll stick with my "economic" solution for now.