hemiguy2006 said:
Frank....
TRC-975 dimensions = 29.5 x 14.5 x 6.
Use box 36"L x 20"W x 16"H. If you keep each dimensional edge at no more than what I suggest, you will have no problem. The dimensions I suggested add up to 108" Length + Girth. I use thick cardboard sheets or large cartons and cut them down. The edges are glued with clamps and carpenters glue. The finished box opens and closes and looks like any other ordinary box. I use a bakers scraper to emboss the crease marks where the cardboard bends/folds. If you enlarge one dimension, you will need to shrink another dimension to keep the total at 108" or under.
This size box will give you room for 3.25" on each side L/R. You will have 2.25" each T/B. You will have 5" each F/B. In my opinion, the 16" depth can be shrink a little as you don't need 5" of cusion material front/back. Play with it to get the size you feel comfortable with.
Type in these dimensions at USPS.com and you'll get the following:
You can't beat that deal. There simply is no justifiable reason, in my opinion, to pay $900 instead of the >$90 price tag for the small difference in protection afforded by any larger of a box. In fact, if the box is too large, I find that the carrier's, due to cumbersone nature, don't handle them well. In any event, I believe a fairly bulletproof carton can be made with those dimensions. Not easy, and it will cost some coin to get the thick materials and foam packing, but for an $800 paycheck/savings, it's worth the effort imho.
