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From what I have been told by a supervisory TSA official, you are wrong on some points, but that could also simply be your experience.
DO NOT USE A TSA LOCK ON THE OUTER SUITCASE.
Airlines that I frequently use DO NOT even look at my weapon. They simply ask you to fill out the card. I PROVIDE TAPE to attach it to the weapon box.
I have NEVER had anyone open up a luggage item once it left my immediate presence. Only in front of me, most often in Idaho.
I wouldn't say I'm wrong, I used to travel with firearms frequently for competitions. It's all dependent on the airline, TSA, and staff. It's always in front of you. I'm talking about after you hand it to them, it still goes through the scanner. As you mentioned, you attach the form to the outer gun box. That still goes through x-ray. Depending on the airline, they'll open up your suitcase see the form and close it back up.
If you have a non-tsa lock on the outer AND inner case, how do they see your form?