modifying flat rate boxes

[e-cheddar]

Occasionally I have to cut up a USPS flat rate box to modify it for a product I sell.  I print a label using the weight and size of the item, using Priority Mail rate, NOT the flat rate that would apply had the package not been altered.

I have one post office (out of two) repeatedly return packages like this.

Any ideas on how to get them to follow their own procedures? 

[sg51]

the post office actually DISAGREES with most posters here.

Scoreboard.

[nowthatsjustducky]

---

@e-cheddar wrote:

unrelated, but what the?:

Q. What if a skillet is packed in an FRB and the handle sticks out?

A. A small bump-out of the box is okay, but if the handle actually sticks out of the box or the box is reconfigured to accommodate the skillet, it cannot be considered as a FRB.

seriously, USPS?

---

Yes seriously.  Things shipped in a flat rate or regional rate box are expected to fit within the box's shape and volume.  If it can not fit within the space allotted, then you find an alternative solution and forget about trying to go flat or regional rate.  Altering such a box would be the equivalent of making a frankenbox out of 2 flat rates, which is also no longer a flat rate package due to it being outside of USPS specifications that they set for their flat and regional rate materials.

[nowthatsjustducky]

---

@sg51 wrote:

the item i have to do this with is about 17" x 4" x 2" long and skinny

You can construct an arbitrarily long frankenbox out of #4's, the 6" cubes.  Just stack them up, and but strappling tape up the long way on all 4 sides.  Then clear tape around them at the joints.

I stock plain brown 4x4x6" boxes, which weigh about 1.5 oz.  They're useful for a whole lot of things, and they also make good frankenboxes.  Buy 100, they're cheap.

---

A pair of the Priority shoeboxes work well for frankenboxing too.  And they don't require a whole lot of altering either, since it is a pretty simple matter to adjust the total length up or down to suit your needs.