Just took this big ol' package up to Fed-ex to send to mini bike mayhem in California.
I really thought it would be more difficult than this! I wouldn't hesitate now, to send another one. Especially like this without the engine.
I first measured the frame of the Duster after breaking it down to the bare frame with even the forks removed. 36.5". I attempted to find a flat screen tv box or a bicycle box. I couldn't find one wide enough.the Duster is about 10" wide at the rear axle.
I then went to my local packaging store and got this box, 38"x33x12, for 17.00. Thing was heavy- duty too.
I brought it home, assembled it using cheap duct tape and just started loading it. I put the bare frame in first then the front tire inside the frame, then I boxed the rear tire and sprocket with bagged chain in a box that fit snugly in the box that will also keep it from crushing. USPS priority boxes seem to work well about, 12" wide! I then put the fenders and other miscellaneous in a box after bagging and cushioning them, duct taped it and sat it on the seat rails on the frame. I then covered the handle bars and front fork with plastic and taped them up. Everything was fit into the box with room to spare. I used empty 12" wide boxes at the top to fill the main box. Ended up weighing in at 70 pounds.
A lot more cheap duct tape, and it was ready to ship. I took it to fedEx and shipped it this morning from Roanoke, Va to California, with insurance,for right at 125.00.
Hope this helps generate more sells on the OldMiniBikes!