That's enough to make me not want to try!

 

Building the box to ship the bottom end to DH, starting with a double-walled 18x18x18 box, only because I couldn't find one stronger.

The secret to a tough box is glue, copious amounts of it.



And an ample stash of cardboard:



Put glue on both sides to be glued:



I got inside the box and stepped it all down well, then piled on some weight; this is just the beginning:

 

Holy smokes that's a lot of boxes!

 

I just snagged the 4 large ones today from the HD shop and some more from the neighbors recycle can. I'll be cutting them all up and gluing to the inside for reinforcement, they'll all get used on this one.

 

I'm sure you have a plan on loading up the case but consider using a few cans of spray foam from Home Depot and a few trash bags. Wrap your case in a trash bag. One trash bag full of foam in the bottom of box, close bag. Let the foam set for a few minutes then lay the case on top of foam bag and let foam harden. Lay in second trash bag on top of exposed upper half of case and fill that trash bag with foam. Close box and allow to foam to harden before checking "mold", sealing up, and shipping out.

 

Ahh, yes, that's worth a try! I was trying to think of somewhere in town where they would use one of those packing foam things but I will definitely look into that, thanks

 

"Great stuff big gap" from Home Depot. I used some 3/4" styrofoam insulation sheeting to line the box and it worked great

 

It's Friday and no matter how boring pictures are they're always welcome on Fridays.

Shipped the bottom end Monday, DH got it today, this is what the box looked like that I promised to show:

The bottom is reinforced, about 6 layers of hard cardboard (the boxes tires come in that I got from the HD shop in town), sides about 4 layers beyond the box itself, corners another layer (all layers are glued to one another-makes for an extremely strong box); a square of about 6-8 layers directly under the cases; you can see the 1 1/4" thick styrofoam-then a layer of cardboard again, I had the chunks of 2x4" so threw them in the corners; then blocks of cardboard glued together on all sides, more for spacers;
under the cases and on top is a garbage bag with expanding foam inside that expanded to help pad and fill in to guard against shifting, and a couple more sheets of cardboard on top before closing it up.








Now just cleaning up the bike whilst I got it stripped down and cleaning up all the parts and whatnot.

 

Nice job! Maybe you should be in the packing industry!

 

Even my old company would have a hard time pulling a "Ace Ventura" on that pkg!!