My wife finally started selling stuff on the internet. One of the big things that distinguishes sellers is shipping costs. If what you are selling (in our case used boutique baby clothes) is heavier that 13oz. you have a lot of options* of how to ship. The same package could cost you $8.60, $10.95, or $4.75 depending how smart you pack it. I was able to package 2 shipments by hand in about 40 minutes. Once I made the jig I could do it in 3 minutes flat.
* Technically you have one les option, since the cut-off for the cheaper first class mail is 13oz. If you can ship first class, you should. It's the best value. So, for packages 13ox and under, I think there is really only 1 choice.
Step 1: The supplies
1. A 12 1/2in x 9 1/2in Flat Rate shipping envelope, price $0.00
2. A strip of plywood* ripped down to a width equal to the shortest dimension of your box, price $2.00 or free (scrap)
3. 8 wood screws 1 1/4in length or longer, price $1.79 or free (scrap)
Table Saw for ripping the plywood (not needed if using a 2x4)
Miter Saw for cutting the sides to length
Philips P2 bit (or T20 if using DeckMate, the only wood screws I use)
Counter sink bit (recess the screw heads, it's prettier)
Forstner bit , Wood Spade , or Auger
* You can opt for a simple 2x4 if you don't have a means of ripping the plywood, but it won't be very useful for stuffing.