Re: Best rifle shipping method?
I used to work for an airline and anything bulky or unwieldy got banged around a little. Not on purpose, it was just out of the ordinary. Air shipping companies, like FedEx and UPS, load cans before putting things on the plane so there are less handling steps so less chance of abuse.
I ship FedEx overnight or 2-day in a Pelican case. No overboxing with cardboard, they accept it as is. I padlock the case. I slip a copy of the FFL both inside the case and into the plastic airbill holder they affix to the case. Since it's domestic they don't need to know what's in the case as long as it isn't illegal or dangerous goods. However I don't drop off at FedEx Office (Kinko's) locations as I was told their corporate policy doesn't allow them to handle firearms, for safety/security reasons I guess (though I also heard this may have changed recently). I just schedule a pickup from my house and the driver only asks if it's dangerous goods. Never an issue.
Their policy, according to their site, states that they will only ship a firearm to or from an FFL (must be FFL on one end or the other). Sure, that seems silly when shipping it to myself, but they're a private company and they do what they need to protect their interests. Besides, I find FFLs that are willing to accept it on their end for free most of the time since they don't need to do transfer paperwork. Also you can't ship ammo with them via Express (air), only Ground, so it can't go with the rifle. My handloads are in my checked baggage when I travel with the rifles.
You should see my Pelican after all its miles. Those things are really worth every penny. It's scraped up but still seals tight.
That said I've also had UPS ship my 10FCP from Bud's in the factory Savage box and it arrived just fine. USPS would be my last resort, if only because their tracking system is so dated compared to FedEx and UPS.