[R-390] Packing Box Info

[Perry Sandeen via R-390]

GM list,
 
This is how I packed my B/A and test equip for its 2,100
mile journey from the 3rd world (TN) to the crazy world (CA).
 
I bought a package of 15 double boxes from U-line 20 x 20 x
12.With shipping I think the price came to around $4 a box. U-Haul and REAL
fedex stores also sell good boxes.
 
To reinforce the box I did the following.
 
I obtained sheets of 4ft by 8ft 1/2 inch high density foam
that is covered on both sides with aluminum foil.  It was about $11 per sheet.  It is very light weight.
 
I then made an inner box with the foam.  First I cut two pieces that matched 20 x
20.  I put one sheet in the bottom of the
box.
 
Then I cut sidewall interlocking pieces but made them 1/2 shorter
than the top edge.
 
Then I’d inset the B/A receiver minus PS and AF module to
lower the weight.
 
I used scrap pieces of foam and packing paper or small
bubble wrap to shore up the sides.
 
Since I many small objects to take, I’d wrap them and but
them in the sides.  Also some of my 3
ring binder manuals would fit in the side.
 
When I finished stuffing the box I installed the foam top
and use the Scotch brand 20X stronger to make three runs abound the entire box.
Each box may have had a net cost of $10 however nothing got damage and I was
able to stack them four high in the Penske truck and sill but lots of heavy
stuff on top of them.
 
Nothing I’ve opened so far was damaged.
 
For some receivers in cabinets I used U-haul of HD wardrobe
boxes.  The HD boxes have thinner sides
and cost less but were adequate for some large items.
 
The U-haul wardrobe boxes were used for several B/A’s.  Packed they were 3 ft high and weighted around
160 Plus pounds.
 
I used both the foam panels and cut up used cardboard boxes
for interior packing.  And the 3M tape.
 
For smaller stuff I  bought120
Home Depot bookshelf sized boxes and built inner boxes for them also.  The reason for the large amount of small
boxes is that no matter what was in them, I could lift them.  With the uniform size we were able to pack
lots of the small boxes in nooks and crannies that otherwise would have been
wasted space.
 
One other packing method was suggested to me but in my case
was not practical.
 
One would take the box and tape in place 6 ea or so 1/2 inch
tall cardboard spacers around the bottom where the B/A edges would touch.
 
Next the B/A was wrapped in a heavy contractor clean-up bag
or builders plastic and taped very well.
 
In the next step one would spray a small amount of expanding
foam insulation in the bottom and rapidly insert the B/A into the box and align
it.
 
Then the box is sprayed with more expanding foam.  The top flaps would be closed and taped. However
a 1 inch hole was previously cut in one flap by the corner to let the excess
foam escape.
 
About a day later one would cut off the excess and wallah
you have a UPS proof box! It it ready to be shipped.  After drying the foam sticks like super glue
to anything it’s touched
 
To open you have to cut all of it away
 
I’ve used this foam in some other applications.  It sticks to your hands like crazy and you’ll
never get it out of a set of jeans or work shirt.
 
Regards,
 
Perrier