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Old Oct 28, 2011 | 10:19 pm
  #14  
chris76
 
Join Date: Oct 2011
Posts: 7
I decided to use the original box to save money, but I am fortifying it. First of all, I went to Home Depot and found a sheet of unbreakable recycled plastic wall paneling that is really thin, yet flexible and totally puncture-proof. I then cut pieces to line the inside of the cardboard box and glued them to the cardboard with spray adhesive. Next, I glued some additional cardboard to the bottom of the box. I then put the TV back in the box and cut styrofoam sheets to provide 1 1/4" of protection at the back and the front and side, in addition to the existing styrofoam supports on the bottom and top. I then taped all the box edges/seams, and I am going to use spray adhesive to glue additional pieces of cardboard on all sides. Then I will use several black plastic box straps to secure the two TV boxes together, and will shrink-wrap them on top of that. The two screens will be facing each other which will protect them from outside damage. The final package will be about 77 inches and will weigh about 58-59 pounds which will only require one oversize luggage fee. I think I'll be more worried about them getting stolen by baggage handlers than getting damaged.
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