For the outer packing of engine boxes I use Costco double wall heavy duty produce boxes. Very sturdy card board. Easily available. Easy to modify. Free. Did I say free?
I try to pick up boxes in pairs or quads. I use the bottom box as is. Wrap the loco box in big bubble wrap. The top box I slice the glued flaps to open the corners with a spackle knife, position it over the bottom box then use a hot glue gun to seal each top flap over the bottom tray.
There must have been at least 25 engines wrapped like that this spring with no damage.
For long stuff like lengths of flex track I use 4 of the same produce boxes. The bottom two I slice open the glue corner flaps then slide them together like a telescope with glued touching surfaces. For the lid I do it a little different. I place the bubble wrapped contents then position the top two same style boxes slid together with glue and let the dry. Once dry I install the top like a shoe box lid, glue in place, and ship it.
At least 6 cartons of track went out like this with no damage this spring.
All boxes go out with a secondary securing of 3" heavy duty package tape.
