Pack and ship
Shipping is where parts profits leak away. Weigh and measure before you list, use the smallest sturdy box that fits, and know which parts to keep local.
Supplies
Free boxes: liquor and grocery stores, office supply stores, Buy Nothing and Craigslist free. Free USPS Priority boxes are for Priority Mail only.
Packing rules (FedEx How to Pack)
- At least 2 inches of cushioning on every side; 3 inches for fragile parts.
- Seal with the H-tape method. Nothing should move when you shake the box.
- Drain every fluid; pad sharp edges, threads and fittings.
- Modules: anti-static bag, then a double-wall box with padding above and below (CivicXI forum).
- Wheels: cardboard discs on both faces plus wrap; box chrome, painted or machined wheels.
- Headlights: box them with foam all around, lenses protected.
Dimensional weight: the big-box trap. Carriers charge whichever is higher, the real weight or the box size: (length × width × height) ÷ 139, each side rounded up to the next inch. A 30×20×10 headlight box bills as 44 lb even if it weighs 9 lb. USPS Ground Advantage only applies this above 1 cubic foot (USPS DMM 283). One seller cut a shipment from about $80 to $40 by shaving one inch off the box (nc4x4 forum).
Carrier cheat sheet
| Carrier / service | Max weight | Watch out for |
|---|---|---|
| USPS Ground Advantage | 70 lb | Extra fees for length over 22" and over 30", or over 2 cubic feet; oversized at 108–130" length + girth; $100 insurance included |
| USPS Priority Flat Rate | 70 lb | Great for small, dense, heavy parts (Medium about $22, Large about $33 commercial) (USPS) |
| UPS Ground | 150 lb | Additional handling over 48" long, over 50 lb, or non-cardboard packaging; Large Package over 130" length + girth, billed at 90 lb minimum (Pirate Ship) |
| FedEx Ground | 150 lb | 165" length + girth max (EasyPost) |
| Freight (LTL) | Over 150 lb | Engines, transmissions: drain fully, crate or pallet, terminal pickup is cheaper. Transmissions average about $300 (uShip) |
Buy labels through eBay while you're new: tracking uploads automatically, holds end sooner, and you're protected on "item not received." Orders of $750 or more need signature confirmation for that protection (eBay).
Never ship: anything with fuel or fuel vapor (USPS bans it outright), flooded car batteries, airbags or refrigerant (Part 2).
Keep local: bumpers, hoods, doors, glass, seats, engines and transmissions unless you've priced freight into the sale.
General education, not legal or tax advice. Fees, carrier rates and rules change; check the linked sources before you rely on a number.