Below is another picture of the block and you can see the clearance in front of the spinner. I did put a foam block over the spinner, but it really wasn't necessary as you'll see on the next page I located the plane using the wing tubes so it could not shift at all in the box.

 

  FYI, building a crate can take from about 4-8 hours from start to finish. My first one took me closer to 8 hours including shopping and travel time, and now it takes me from 3-4 hours.

Alternate Methods

1. Pack it in peanuts. If you have access to cheap Styrofoam peanuts in bulk, instead of all the foam wrapping and support, all you do is fill your crate, or cardboard box, full of peanuts, with the plane and parts floating in the middle. You do need to make sure you have ample clear space around the plane, but this is about the simplest, and yes, the safest way to "secure" the plane in your crate/box. I've received multiple GS planes from the Asia Pacific region in very large cardboard "crates" filled only with peanuts, and they've all arrived without any damage. BTW, the plane and parts stay put in the peanuts, they do not ship around during shipment, but make sure the crate/box is packed full.

2. Use the original cardboard boxes, or make your own. For up to some 33% planes, you can ship in multiple cardboard boxes. It usually takes three. One for the fuse, one for the wings, and one for the engine, cowl and accessories. With this method you can ship up to some 33% planes via UPS/Fedex or Greyhound  for around a total $50 - $80.

This is a picture of an H9 33% Extra fuse in a cardboard box I modified from the original shipping box. You can see the Styrofoam pieces I put in to help prevent the box from being crushed. The box just fit within the size restrictions for the above mentioned carriers. I did have to cut off the hinges for the rudder, which of course would have to be re-attached by the buyer, but that's a fairly simple task to have to do for the benefits gained shipping in this way. For the wings I used the original shipping box (you could make one pretty easily too), and for the cowl and engine I just bubble-wrapped them carefully in a third box.

BTW, I typically fill the boxes with peanuts to be extra safe.

 

 

 

Shipping

Carriers

UPS/Fedex Ground

Maximum size: 165" - Length + Girth.

Girth - The distance around your box at its widest point.
Length - The longest dimension of your box.

Maximum length: 108"

Maximum weight: 150lbs

USPS

Maximum weight: 70 lbs
Maximum size: 130" - Length + Girth

Greyhound

Maximum size: 30 inches X 47 inches X 82 inches.
Maximum weight: 100lbs except with select routes it is 150lbs

Maximum insurance: $1000. This usually works out ok if you use the alternate method #2 above, though you have to send them each as a separate shipment.

Forward Air (www.forwardair.com)

Pretty much unlimited size and weight. Remember, they go by dimensional weight when figuring costs on these.  In other words, with our relatively light content, you typically will get charged by the size of the box rather than the actual weight....so keep your crate as small as possible if you're shipping by Forward Air or any of the trucking or air freight companies.

Special considerations: Forward Air requires room under the crate for a fork lift to pick it up. All you need to do is screw on a couple of 2X4s to the bottom. 

Other Trucking lines

Same as Forward Air, except typically more expensive, though you can get door-to-door service.

Air Freight

Southwest Airlines Cargo - This is the only one I've used, but others are available.

Maximum weight: 150lbs
Maximum size: Must fit in their cargo door - I don't have the max dimensions, but the crate in this article fit.

Multiple crates can be shipped for one freight charge.

Levels of service: Same day, 24 hour guarantee and standard freight (cheapest).

Standard means it gets on the next flight space permitting. I used standard freight and I dropped the crate off with Southwest at 11 a.m. and it arrived in Tucson the same day at 4:40 p.m. The crate arrived in perfect shape. Rates can be relatively reasonable, even less than truck rates in some cases, so it is worth checking into if you're in a hurry, or the delivery location isn't too far away from you.

Special considerations:

1 - Southwest doesn't want anything on the bottom of the crate, such as runners for fork lifts as required by Forward Air. This is probably the same for all air freight companies because of the limitations of the cargo doors and loading methods.

2 - One thing Southwest didn't tell me before I took the crate in, is that you have to open it for inspection before they'll take it.

Insurance

Buy it. As mentioned before, take pictures of the contents before closing the lid. It is very important to have this documentation if you need to file a claim. Each carrier handles insurance differently, and they're all pretty difficult to deal with, but you can get claims settled if you have your shipment properly insured and documented.

Examples