Question for the experienced here. What is the best way to ship forks? Make box and fill with packing paper? Long Rubbermaid tub?
+1 to the case. Though I put the case in a box too. My friend brought just the case in to be shipped, but the employee didn't know if they could or not. She called her boss and started the conversation with "so there's a customer here, and it's not a gun...". Brilliant.
Remember that UPS will add a stupid surcharge if it is not cardboard, so wrap the gun case in cardboard or send it FedEx.
Spray in foam insulation/sealant, aka Great stuff. Get your self a box ... Spray some foam into the bottom of your box ... (If this is the first time you have sprayed foam in a box, go slow, it might be surprising how much it expands ... ) Before the foam sets, place a plastic barrier (use one side of a big garbage bag) over the foam, and 'snuggle' the forks down into the foam. After the bottom foam sets, place another plastic barrier (the other half of the garbage bag) over the forks, and spray more foam into the box. Let it set, and then trim to fit. Leave enough foam that the box fully closes, and firmly (yet gently) holds your forks. The plastic keeps the foam from sticking to the forks, and allows the 'return' shipping, in the same box. Remember, that if you take good care of your box, it will allow you many happy shipments ...
No, there's plenty of padding, go to wally world or some other place that has them on sale. Tape the catches all the way around, wrap it in cardboard if you feel it is necessary.
I just bought a Cabelas 'Double Rifle' case, it was on sale. Shipped it UPS via Staples. I ziptied it at the lock points, and it is clearly marked 'not a firearm' on the label.