USPS now offers two 70-pound Priority Mail packs. One is about the size
of your head, and the other is more pizza-box shaped. Each costs $7.00
(!) to mail intra-CONUS. What a screamin' deal!
Flat-rate boxes. They're $7.70 postage and a free box. The boxes are way
too weak to hold much more than a few pounds of metal, so we wind up hot-
melt gluing corrugated reinforcements. I've shipped 40 lbs of metal this
I frequently use these , they have four different sizes and a flat rate
envelope for 3.85 as well, the greatest thing is you can order the boxes for
free and print your postage out online and give the packages to your
Not sure about that one, in my experience postal workers don't even
flinch at oddball packages. An example are my (in)famous CTUs a.k.a.
cookie transport units a.k.a. cookie pipe bombs.
These are 12" long pieces of 4" dia PVC drain pipe with end caps taped
on, they get nice printed mailing labels and standard "packing list
enclosed" envelopes that contain the delivery card. Internal packaging
is a wrap of bubble wrap around the plastic freezer bag containing the
cookies and foam inserts in the end caps.
I've carried an entire paper case full of about 10 of these into the
post office to send off priority mail during the holidays and while I
got a lot of odd looks from other folks in line I didn't even get a
blink out of the post office folks. I've never had a report of a broken
cookie on the receiving end either.
Kind of like when I mailed a 1 litre liquid nitrogen dewar to
Switzerland. Postmaster asked what it was, if he could see it. Looks,
well, kinda bomb-like to be honest. I've sent tons of oddball stuff out
by him (he's also the window clerk, mail sorter, and sometimes delivery
guy - small towns are great). I got "the shrug", a "nice packing,
that'll be fine" and off it went. But, we wanted to know what the heck
a dewar was, and suggested I call it a "bottle" on the forms. So it
went out as "empty insulated bottle" and "used lab equipment".