First off, we need some materials.
Corrugated board, masking tape, filament tape, box sealing tape, frame
corner protectors, banding film, and 1” thick expanded polystyrene
(EPS) foam. This product is readily available in many sizes through any
Get it there
in ONE piece
Why not just get a big box,
put your piece in and dump some “popcorn”
in for padding? Two reasons…first, when (if) the piece arrives at it’s
destination, all the popcorn has settled to the bottom and has been
totally ineffective for most of the journey. Secondly, the
dreaded “oversize” category can creep up on you quickly.
Exceeding the guidelines for regular parcel measurements can easily
have you paying 150 pound rates for a 25 pound package if you‘re not
careful. For regular shipping rates to apply (with UPS), packages
can be up to 165 inches in length and girth combined (length = longest
side, girth = width x2 + height x2).
The beauty of the custom box lies in it’s ability to protect the
contents, while keeping the parcel’s overall size to a minimum.
Our patient for the box doctor
today is an oversize $1000 bill with
poker chips and cards destined for Chicago. The outer dimension
of the frame is 26’ X 48”. Note…
If your item to be shipped requires glazing, and you have the
option to use acrylic instead of glass, do so.
Keep in mind that all
the little precautions add up to a successful outcome.
STEP BY STEP…
1). Inspect, clean and
do your final touch-up’s.
2). Use some thin foam or small bubble
wrap on your frame corners
(under the corner protectors) to avoid any marring, sometimes caused by
the protectors themselves.
3). Secure corner protectors onto your frame with banding film, more
commonly known as “stretch tape”. If you don’t have this product,
SOME. Stretch tape not only holds your corner protectors on, it
protects the frame finish, allows you to bundle mouldings or spacers in
the shop, holds problem corners together while glue is drying,
keep length moulding from warping, plus a million other uses.
|4). Measure the outer dimension of your piece.
Our project including the corner protectors is 26 ½ x 48
5).Cut 2 pieces of cardboard that are 2 ¼ inches larger all
around than your piece i.e. 28 ¾ x 50 ¾.
6). Use the cardboard as a stencil to cut your 1” thick foam
These can be scored with a sharp blade and snapped or broken off since
your blade will not cut completely through.
| 7). Tape the cardboard(s) to the foam(s) using
the front and back pieces of your box.
Put them aside for now.
8). Measure the thickness or height of your
piece (our example is 1 ½” high).
Cut cardboard pieces that are the
height by whatever your longest side is.
We will be using 2 pieces
that are 1 ½” x 50 ¾”. These are your 2 long
sides. Repeat step 6
with these pieces.
both of the sides on the edge of the
Measure the distance needed to get to the opposite outer edge.
Cut cardboard to that length by the same height as before (1 ½“
example requires 2 pieces at 1 ½” x 26 ¼” to make the
Repeat step 6 again with these.
masking tape, secure all sides to the
bottom piece by coming from the bottom up and over the sides. Also tape
horizontally around the corners. This will leave you with a self
contained shell that your piece will fit into.
11), Lay your piece in the opening and pray that you don’t see it again
(most important part this project).
12). Put your top piece on, and this time with filament tape, come from
the bottom, up and over the top.
Re-enforce your corners horizontally
also with the filament tape.
13). Using the box sealing tape, cover the
filament tape making sure to extend over the ends. If there is a weak
point in this project, it will be that the filament tape tends to give
way starting at the ends, with dust on the cardboard or
humidity changes generally to blame.
Completely covering the filament
tape with box sealing tape
will alleviate this problem.
14). Apply box sealing tape to every place you see foam meeting
cardboard all around. This will seal up the box nicely, protect the
contents from the elements and add a final bit of re-enforcement.
15). Using a black marker, make a line all around the box where the top
foam meets the side cardboard. Make a reference on the box that
“To open: Cut along black line only”. When the black line is cut,
top will be easily removed, leaving the contents face up, and the rest
of the box intact.
Packing multiple pieces with several layers or levels inside your box
is also easy. The height of the sides simply needs to reflect the
total height of all layers to be included. Cardboard is fine for
the layering and actually adds stability to the box shell. To
layer pieces, refer to #1,2 and 3 above and measure the outside of your
largest piece. This will determine the box length and width.
Cut cardboard layers that are 1/8” smaller than the box opening to
accommodate the appropriate number of pieces to be included. Fit
the smaller pieces on each layer like a puzzle and fill the empty
spaces of each layer with scrap EPS. The goal here is two fold,
first, to keep the pieces from moving on each layer and secondly, to
make each layer as “level” as possible within the confines for the box
Stack all the required layers on top of one another and get your height
measurement for the box sides, then go to #8 above and have at
it. When finished, all the layers inside make this box virtually
We have clients that re-use our custom boxes for traveling art
exhibits. Some boxes have been back and forth across country 3 or
4 times, housing 10+ pieces of art with the boxes weighing in excess of
90lbs each. Now that’s a box!
We have shipped up to 60 X 90 X 15 using the above guidelines without
The 1” EPS version (described above) is fine for pieces up to about 40
pounds. When you get into the 50-90lb range, you will need to increase
the layers used on your sides, and replace all cardboard mentioned with
Gatorboard or equivalent. Regular white foam-core can always be
substituted for cardboard when “pretty is pertinent” and further
towards that end, don‘t forget the white filament tape instead of cream.
United inch pricing of length + width + height times $1.25 is the
current rate for building a box that houses one piece.
More than one piece can be shipped in the same box for an additional
Best of luck to you all and… happy boxing.
See our Law Enforcement and Military Website at www.BadgeFrame.com
New-Frame / National Toll Free
© 2005 Baxter's Frame Works /
Frame / All
Ave., Suite A Chino, CA 91710
Local (909) 591-3033
forget to sign
before you bail.