Outlandish bro,

I do not think it's worth to drive to Kathmandu from Delhi just to save some money??? How much do you think you'll save doing that plus the trouble of the long drive, luggages, many possible hassels at the airport (if you check out the luggages in Delhi, the Indian Customes might give you trouble), hassels at border points like you said. do you really think it is worth just to save $200-$300????

If you really want to save money, have someone get you a ticket from Kathmandu for the DEL-KTM route and then fly on that. It's usually quite cheaper to get DEL-KTM ticket from Kathmandu than from here. But, on the contrary, if you get the entire route's ticket from here, you don't have to worry abt anything--just enjoy your flight.

Good Luck