My AFCK mini has only been turned away once. The guard found the combo blade "menacing."
A lot of people go on and on about how FAA rules allow folding knives up to four inches and about how California courts have found that serrations alone do not make a knife menacing. But, the FAA rules basically allow a guard to disallow anything or anyone he wants to. If the guard doesn't like the color of your knife, it's outta there. If he doesn't like the look in our eyes, you're outta there.
When my AFCK mini was turned away, I simply walked back to the ticket counter, handed the knife and my tickets to the clerk and he checked it through. I claimed it with my baggage just fine. They have boxes just to take stuff that security turns away.
On my last trip, I took my Rekat Escalator from Portland, OR, to Dayton, OH, via St. Louis, MO, and then back. No problems. I just dropped the knife into a change tray along with my Leatherman PST, my watch, keys, and any change, etc. and handed it to the nice guard as I went through. I collected it all up on the other side each time without comment.
My secret is this: realize that the guards are profiling big time. They see each passenger for a matter of a few seconds. They necessarily judge each book by its cover. So, first, dress well. If you come through in army boots, camo cargo pants, and a black tee shirt that says, "I don't use 911, I use 9mm," (actual shirt seen on a person who was being all but strip-searched by airport security) don't be surprised if they take a dim view of you and your weapon. Nice looking shoes, slacks, a dress shirt, and a tie are the way to get through. Second, smile. And, finally, be polite. Make a point of allowing the lady in line behind you go ahead. Act like a gentleman and suddenly any tactical folder you may have becomes a little gentleman's pocket knife. If they're judging my book by its cover, then I'm gonna wrap myself and my knife up in the nicest cover I can.
If you are asked about your knife, answer politely and with a smile. Open the knife slowly and with both hands. Don't open it far enough to lock. If asked why you're carrying it, say something like, "Oh, it was a gift from my late wife and I always have it with me. I keep my nails trimmed. I have terrible calluses on my hands that I need to keep trimmed. And, God forbid, there should be a plane crash, well, I might need to cut my neighbor's seat belt to help him get out."
Whatever you do, don't make a public scene. The guard's motivation here is security -- not your security, but his own job security. Security guard at an airport is a good job. It's indoors, there's no hard labor or heavy lifting, and it doesn't involve raw sewage as so many of the other jobs people of this education level qualify for do. The biggest threat to the guard's job is obviously letting a weapon through, but
when was the last time a plane departing the US was hijacked? No, the bigger threat is members of the public complaining about him. So, start by politely addressing the guard by name. It's on his badge. Say, "Good afternoon Jose. Is there a problem?" The is subtle, but, in a very non-threatening way, it says, "I know your name." It's one thing, though, for Jose's boss to call him in and say, "Jose, I just got a letter from a passenger who came through here last Wednesday. He's complaining about you and says you refused to allow his little pocket knife through and that you were rude to him and that he almost missed his flight because of you." Jose will say, "Last Wednesday? A knife? Oh yes! I remember. That was no little knife. It was this big [hands held up a foot apart] and it must have been some sort of switch blade because the blade just jumped out of the handle right under my nose. Scared me to death. And that guy -- he was a strange guy. There was something about him that made me really nervous. I just really didn't think it was safe to let him carry that big knife on a plane." The boss's response: "Good job Jose. We can't have crazy people carrying huge switchblades on airplanes. Well done." Jose dodged that bullet.
But what if you made a big stink in public and Jose let you and your knife through. Now, the boss is going to get a dozen letters reporting that Jose let a mad man with a huge switchblade through just because the man intimidated him, and they didn't feel comfortable and safe on their flight as a result.
The guards are supposed to error on the side of safety. So, if you make a big stink, you put the guard in a no-win situation. If he turns you away, you complain. If he lets you through, everyone else complains. The lesser of the evils is to turn you away. So, don't put the guard in that position.
Finally, be prepared to take the knife back and check it through if necessary. This just means allowing some extra time.
Chuck