Originally Posted by
FBinNY
The most important thing to do whenever you pack a frame or bike, is to put pacer blocks in the fork and rear dropouts. Properly braced these are strong and travel well. Not braced they're prone to crushing. You can make a brace with a piece of 2x1 and 2 nails, or get one free at any bike shop (fronts are much more common than rears).
I assume you mean "spacer" blocks, and I agree. I often make them by rolling up corrugated cardboard. In a rolled up state, it is very strong. Or you can scrounge them at a bike shop. They receive them when they receive bikes from their suppliers.
For shipping a bike crated in a single box door to door, FedEx beats UPS and USPS by a lot. If you want to spend even less, bring it to a Greyhound station and ship it there. The recipient has to pick it up at Greyhound on the other end, as Greyhound doesn't pick up or drop off. But it's a nice way to save money.