Another thing a buddy of mine does is watch for the big box stores to have the cheap plano hard gun cases on sale for $15. It happens a lot! Then he wraps the case with cardboard, essentially making his own box (dont use paper!). Using duct tape to pack it helps. If you just have one to ship its probably cheaper than buying boxes, might even be able to charge a few extra bucks for the added case to the buyer.
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