There have been a few tutorials lately, here is how I box a chassis for shipping.

tron guy

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I start with a little bubble wrap around the neck board.
Then a good piece of cardboard that covers the entire bottom of the chassis and folds over the top of the flyback.
Next I wrap bubble wrap horizontally, dropping the neckboard and anode cup between layers. Then a vertical layer of bubble wrap follows that:

Next it goes into a medium flat rate box. This is the ONLY way a medium flat rate box being used in shipping a chassis is acceptable!!!!!.

Then a bigger 200lb or strong box is next. In this case I used 2" thick foam, other times I use bubble wrap, or peanuts. All work fine.

Put the medium flat rate box on top of the padding. Then I use really heavy duty cardboard and fold it for each corner for extra protection in the larger box. Again sometimes with packing peanuts, this time I used a little bubble wrap. Sometimes, I wrap the entire medium flat rate box in bubble wrap.

Drop either some packing peanuts, or additional styrofoam protection in the sides. Then in this case some 2" foam that matches the bottom, on the top, and she's ready to go.

I'm not saying this cannot be damaged. If someone was dedicated enough I'm sure it could be. But I am on a streak of over 300 chassies shipped without a report of a break or issue.

It is a LOT easier to do this for 10 minutes than deal with someone who received a broken chassis from you, and the nightmare with insurance, etc... ( even if you get paid twice to fix the same chassis*)

This is one way to do it.

*almost nobody will get this toolbag reference.
 

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