Pack It Right
Hey the liquid idea is great, hadn't thought of that. Best solution is to number one, not use UPS :thumbsdn: . We've shipped a few thousand packages over the past five years and UPS lost our business EARLY, they simply abuse items, many other shippers concur, ask around. Believe it or not, USPS (the Post Office) didn't damage a THING in about 800 packages, but their fees went way up and we switched to FedEx Ground a couple years ago, our current carrier. Most of our stuff is large or heavy so the PO scored great with those packages :thmbsp: .
For a volume shipper, 'quick and efficient' are both musts, so we always use new boxes bought from a local supplier, we stock tons of sizes. But the U-Haul moving boxes and other stuff is great too. Most important, strength and padding, regardless of what it is. For heavy items, STYROFOAM, in fact UPS refused an electronics damage claim we had once because it was packed in 4" of 1/2" bubble wrap rather than their REQUIRED styrofoam, which incidently wasn't posted ANYWHERE by UPS as a requirement to secure insurance compensation :worried: .
Anyway, now we use very oversized boxes, on heavy items allowing for at least 4" of foam on ALL SIDES (top and bottom), though we've gotten by with as little as 2" on sides for certain items. We first wrap EVERYTHING with 18" pallet wrap, comes in rolls for about $20 that will last most people a couple of years. The pallet wrap seals the entire unit and gives it initial 'rub protection'. It also really helps to strengthen everything, hold cords and wires tight, keeps knobs intact, etc., making it easy to drop into a box. Makes a good impression on the buyer too

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Next we load up the bottom of the box with several extra inches of styrofoam peanuts, then jiggle the box to settle them and pack them. We drop the unit in and wiggle it down so it sits several inches above the bottom of the box, the heavier the unit the more inches you need on the bottom. With luck the carrier won't flip the box over and the bottom packing will absorb all the abuse along the way. Center the unit in the box, then pour the peanuts all around the sides. Jiggle the box again to settle them in and pour again, covering the top several inches deep. Remember the carrier or automated distribution centers may flip the box over so the top then becomes the bottom, so pack for it. I've found that the heavier the box the less likely it is to be flipped over. Remember, PEANUTS SETTLE, so don't pack them loosely, otherwise they'll all flow to the sides and bottom and the top will be unprotected, or the unit will shift to one corner or bottom, take a hit, and all is lost

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Do your best to once again jiggle the box before you tape the lid flaps down, then over fill the box slightly with peanuts. You want the lid to fold down snugly, then tape it tightly. Tape ALL the seams of the box, across the center and two of the sides of the flapped ends, PLUS the glued seam on the side corner. On heavier boxes I sometimes even tape EVERY corner seam of the box, to add strength for enroute hits and handling and prevent bursts, and usually lay two or three strips spaced across the top and bottom, sort of like straps, to add extra strength, sort of the same theory of taping windows in a hurricane. I hate to use the term gorrilla proof, but remember your carrier may be on his last week with the company and getting his revenge, it happens :worried: .
Now the thing a lot of shippers give no thought to is the label placement. But I put it EXACTLY where I want the carrier to reference it from, depending on the weight and shape of the box. I want to be sure the bottom stays on the bottom, so on stereo components the label will likely be topside, toward one side, with the label being readable from the side it's toward (not upside down). If the label is flipped around the carrier may stand and store the package on the side so he can read it while packing it in the truck. Label placement is very important.
Some amps are very heavy to one side so that may figure into your packing strategy. It will naturally want to tip or fall to the heavy side, so if it is VERY top heavy and not real wide pack it upside down in the box so the heavy part is always on the bottom. That will prevent flip overs, sort of like the blow-up punching bags that are weighted on the bottom; punch it and it returns upright, heavy side stays down. If the unit is VERY side heavy, either pack the box with that side down, or place the label on that top side so the carrier can rest the heavy side against himself while carrying it and reading the label. If the weight is on the other side he'll drop it as it rolls out of his arms :worried: , then mentally blame you for not packing it well if something is damaged :sigh: . Use more peanuts on that heavy side, because the carrier may well store it in his truck with the heavy side down, regardless of any arrows or 'this side up' instructions you have on the box.
I shipped a vintage boat motor, packed strategically, and had arrows and 'this side up' all over the box. I handed it directly to the driver and the first thing he did was lay it on its side, right in front of me, as he fit it into the layout of his truck. He totally ignored the labels without a thought.
Now all of this seems expensive or otherwise, but if so you have likely never had to handle a damage claim or deal with an angry buyer :worried: . Think 'overkill' when packaging, don't assume you'll have a caring driver; machines do much of the work, drivers get tired and hurried. Besides, a $500 amp deserves good packaging, a small part of the overall price. Be sure to charge enough for shipping so you won't feel you have to cut corners. iShip.com (
http://iship.com/priceit/price.asp) is a good source for general price quotes to base your shipping fees on :thmbsp: .
The solid foam boards are a good idea, make sure they're thick enough all the way around. But they can be expensive and timely, and as mentioned transfer shock to the unit, the reason many manufacturers only do the corners. But for speed, cost, and efficiency the earlier method works great. FYI, for lighter items such as cassette decks or CD players, several layers of 1/2" bubble wrap works great, all the way around the unit. We buy 24" wide wrap which is 'perfed' every 12" for tearing pieces off. Usually you can wrap the unit several times with the bubble wrap then fold the ends over and tape them down. If the unit is wider you can tear off a couple extra sections, roll them up, and tape them to the ends of the unit. Then drop it all in the box same as before, making sure it WON'T MOVE AROUND. No movement is critical with any package, if it moves the dynamics can be greatly increased when a box is dropped, creating forces that will overpower your padding :sigh: . Always ask yourself the question, "If I were packing this to ship home to myself, will this be good enough?" :yes:
That was the short version, tune it at 11 for a full report... :thmbsp: