The Costco brand rollerboards are a great choice. They are inexpensive, and last forever. As for packing, I try for 50% fill outbound, that leaves plenty of space for knicknacks that I buy on the road. Every month or so, I look at each item I have packed both in my computer bag and in my roller, and ask myself if I have ever used it... If the answer is no, I leave it.
FR