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My previous board bag survived a couple of flights before being too thrashed to travel reliably. Then I got this one. This one has put up with airline abuse really well--no seams blowing, no busted zippers, no massive gashes in the material. In fact, none of my gear has received any wear from flying when in my Gig. So the padding is more than sufficient. If you are still worried bumps and bruises, save yourself the worrying and put a coat or towel around your board. If nothing else it will help you sleep better on the plane.

I'd go with the 166. That's what my wife and I haul and storage our boards and a good amount of gear in. I ride a 160 and my wife rides a 156 and we put the extra bag space to good use. I've used the bag with only my board and I didn't need any other luggage--checked or carry on. It fit everything I needed for my 3day trip. If you are wanting to pack cloths/gear with your 157.5 into a board bag, then I would suggest this bag and size 166. I hope that helps.

Stellar Bag, lame shoulder strap
5 5

My Wheelie Gig has toted my wife and my gear on the road and on a few flights. Airline abuse did in my last bag (burton board sack) but this one has held up really well--even with our 166 Gig packed full. It's durable construction, for us, had one exception: the shoulder strap broke the first time we used it. Still, my wife and I give the Burton Wheelie Gig Bag top marks. For us it's the perfect balance of size and portability.