When I shipped Gustav off to Japan last summer for his photoshoot, I recorded my packing process. The wooden box was hand-made from 0.25″ plywood, sized to fit the aircraft and remain under the 12″ x 12″ size limit required for International Small Packet shipping.

To secure the model within, pick-a-pack foam was used as I can easily tailor it to the exact shape I need, while leaving excess space around delicate areas. 

To ensure the kit was unpacked safely, I also included several fly sheets outlining areas to watch out for — aerials, pitot tubes, etc.