what to get for storage.... Discuss what to get for storage..., on ChipTalk.net the place to go for your Poker chips and gambling tips. Read it in Home Game General.
You should be able to fit 2 400 chip cases side by side in a single layer into a suit case. Alternatively there's always the option of using racks (if you don't use covers, I'd suggest using a tape gun and going over the chips with one-two layers of tape. (but you might need to bring some tape with you if you're bringing the chips back).
If they are being packed with clothes all around them, it would probably be your lightest option to pack 8 of the cardboard 100 count chip boxes (like those lovely pharaohs came in )
Of course they would be loose but if you wrap them in a heavy plastic or cloth bag I think it would work nice...I brought a loose mah jong set of similar weight to the 800 faux clays and packed them in my carry-on wrapped in clothes...
cheers and have fun! costa rica sounds fantastic and I am planning a tip there myself next year!
KY 70's post reminded me of something. 5Star usually ships the Chinese chips in cardboard boxes that hold the 50 chip shrinkwrap tubes fairly well. Unless you need to bring cases as well, you might just want to leave the tubes of chips in the boxes that they ship in from Trademark.