Packing ten Atlas switches for shipping using produce trays

In response to:

@Allegheny posted:

Hello Tom Tee,

Sounds like you have a good system.

Could you please provide a couple example photos as it would go a long way to help visualize your packaging description/suggestions.

Thanks!

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...This is continued from the Lionel out of warranty service thread, thought best not to totally hyjack the OP's thread.

Kazar, although this involves ten Atlas turnouts instead of an engine the treatment of produce trays for an outer shell is similar.

The first thing I did was to tape half of the switches on their own backer board then wrap each switch and board with small bubble wrap .  Then stack five individually wrapped LH switches and tape that stack together as one tight pack.  Repeat this for the 5 RH switches.  Lay in a triple layer bed of large bubble wrap and pack the sides with air bags.  Now the surgery commences.

Tools: broad chisel,  3" serrated  adhesive knife, hot glue gun w/ 3 glue sticks, ratchet strap, two squeeze clamps &  two 16 oz chilled Snapple ice tea.

Slice all 8 corner tabs freeBoth inside and outside tabsThen remove the inside tabsCheck for centered positioning

Pre heat the gunRachet strap the lid length wise

With the box laying down, clamp the starting corner firmly, lay the long flap out, spread four lines of hot melt then quickly upright the box and press down for a few minutes.  Repeat for opposite side, then repeat for the short ends,  then glue the four remaining out side corner flaps.  Firmly hold each hot glue application.

Finish up by checking for any non touching spots and let set up.

The box is now ready for redundant taping and drop off at FedEx.  My instructions for recipients are to cut the top flat surface around the  perimeter on three sides with a box cutter for a lift up access hatch.  It can be reused as a closable container.