WA4GEG contents; Packing in Yaesu boxes, how-to pack in other boxes, & misc.

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  Safe "drop-kick-proof" shipping is no accident, it is achieved by careful attention to proper packing as detailed on this page. 

  Shipping info: 

For shipping your transceiver I recommend using FedEx's Ground Service, available at FedEx Office Centers everywhere. There is also the option of shipping via FedEx Ground from their website, FedEx.com, and arranging for a pickup at your QTH. Your other carrier choice is the Post Office which tends to be more expensive on insured item value (not recommended).

ALERT for those shipping via the Post Office. In the event of a failed delivery (i.e. no one available to sign for the pkg.) the Post Office does not automatically schedule another delivery date. One must manually schedule the re-delivery date. It will be most helpful if you will keep a close eye on your USPS tracking and immediately give me a heads up if they are unable to deliver, which can and does happen should I be out on a service call, or running noisy equipment that masks a gentle knock at the shop's door.


Please Note: all outgoing shipments from my business are shipped via FedEx Ground Service, shipped on my FedEx account. I do not accept prepaid shipping labels, nor will I ship on an account other than my own. All shipments to my shop must first be authorized by me, which is done at the time I'm booking your service appointment.

Shipping address:    EES/Byron Campbell
                                        126 Stiner Shores Rd.
                                                Sharps Chapel, TN 37866

NOTE: The original Yaesu "insignia" factory shipping box must be complete with the custom molded foam pieces. Substituting other materials in place of lost molded foam guarantees shipping damage, and that I'll be forced to charge a hefty fee for properly re-crating the transceiver. The integrity of the factory shipping box depends on those custom molded foam pieces, including the spacer (3-foam blocks on strip of cardboard). And because of the age of factory boxes, it is standard practice to "float" them (in packing material) inside an extra heavy duty box (size 24x24x14 inches) to take the wear and tear of shipping, not to mention adding vibration damping.

Packing info. for the original Yaesu factory box:

100-Watt versions of the FT-1000MP line of transceivers; When placed into a new heavy duty triple-wall double-corrugated outer box, these rigs ship nicely in their 16 to 25 year old original "Yaesu insignia" bearing factory boxes with their custom factory molded foam packing.

200 Watt Mark-V FT-1000MP: it is mandatory to use the complete factory box set including the approx. 32x21x11 inch outer box, or a new heavy duty triple-wall double-corrugated outer box, commonly available in *24x24x24 size, *but prepared by reducing the height to about 13 inches. This is best done by cutting free the 12x24 top closure flaps, place them around the inside perimeter to double up the box's sidewall thickness, and you then have a nice guide for forming new closure flaps from the box's side portions that extend above the doubled sidewalls.

Before use, do inspect the condition of the factory boxes. Reinforce ageing tape on the bottom flaps with fresh box sealing tape. And for the inner "nested" boxes with only metal staples holding the bottom flaps, remove any loose or damaged staples and securely tape all seams.

Please observe the packing check list:

1 - Collapse the adjustable front bottom feet on the transceiver (if extended.)

2 - Tape (Scotch tape) the top hatch door closed.

3 - Install the protective plastic wrap around the transceiver first, then fit the molded foam packing (or use 3 mil. or thicker plastic wrap, plastic bag or similar.) Without the plastic wrap, the molded foam packing will tend to burnish the cabinet finish, make foam dust during shipping vibration, and etc.

4 - Place the radio package (transceiver plastic-wrapped and fitted with molded foam packing) in the shipping box.  Factory boxes include a spacer consisting of 3 Styrofoam blocks attached to sheet of cardboard; this spacer fills the gap between the box and radio package, and should have its cardboard side facing the radio's front panel. If the spacer is to tight to fit then the radio package needs to be rotated 90 degrees. The factory box may at a glance appear to be square, but one dimension is shorter than the other, so everything properly fits only one way.
5 - Include a note containing your complete return shipping address and contact info., plus a short description of the problem and any additional desired service.

Your original shipping boxes will be used to return ship your transceiver. I make a point of always returning original boxes to their respective owners.


Non-Factory Box Packing Notes and How-To

NOTE: When using commercial and office center packing services, “avoid like the plague” the low tier economy packing which uses a ton of heavy crumpled paper void fill and one-way light-duty undersized boxes that guarantee some amount of shipping and or G-force damage. Damage claims are denied for improper packing no matter who or which firm does the packing, including office center employees. Assuming your transceiver arrives damage free, you'll end up having to pay yet a second time but for proper boxes and packing materials.

Do it right the first time around, going for the packing service's higher tier price point that employs packing foam-peanuts or expanding foam-packs for void fill, and or bubble-wrap, in heavy duty thick-walled double-corrugated reusable boxes, the outer box measuring no less and no more than 24 x 24 inches on the sides. And to insure that they use the proper materials, and NO PAPER FILL of any kind). You have to watch them like a hawk. The really inexperienced packing personnel may need a good bit of hand holding.

DIY Packing: The important aspects in double-box packing of the FT-1000MP series rigs is that the recommended minimum and maximum box size of the second or outer box is 24 x 24 on the sides, and no less the 13 to 14 inches in height, and that there is at least 5 to 6 inches minimum clearance between the face of the VFO-A main tuning knob to the outer box side. Additionally, it is important to not have any packing materiel in contact with the face of VFO-A or VFO-B knobs nor the immediate front panel area surrounding those knobs.

I.e. only have supporting packing material in contact with the first 4 inches in from the left/right front panel edges. Large bubbles (1/2 to 1 inch diameter bubbles) bubble wrap or expanding foam-packs works well. Foam-peanuts may be used for the center (front panel) void fill area. The technique is specifically to protect the Key Unit (press switch) circuit board embedded in the front panel, which is easily and often damaged when shipping in undersized boxes with insufficient clearances.

Packing steps:

1 - Collapse the adjustable front bottom feet on the transceiver (if extended.)

2 - Secure the radio's top "hatch" with a single strip of Scotch tape.

3 - Wrap protective plastic around the transceiver (3 mil. or thicker plastic wrap, plastic bag, or bubble wrap)

4 - Attach a note containing your complete return shipping address and contact info., plus a short description of the problem and any additional desired service.

5 - Double box as per info. below:

Boxes required for double boxing:

  • Inner box, minimum size 18 x 18 x 8 inches, either single or double corrugated.

  • Outer box, minimum size: 24 x 24 inches, 14 inches height, heavy duty double-corrugated triple wall

Double corrugated, triple wall is MANDATORY for the outer box.  24 x 24 x 24 adjustable height boxes can often be sourced from most FedEx and UPS customer counters. U-Haul has a nice quality 24 x 24 x 20 inch double corrugated triple-wall box, link here:


Recommended Packing materials, most any combination of these may be used:

  • Medium to heavy duty (synthetic foam) packing "peanuts",  about 4 to 6 cubit feet. AVOID Starch "Tater-Tots" style peanuts which are too soft for this application.

  • Bubble-wrap, 1/2 inch bubble size or larger, about 50 feet is typically required.

  • Or Versa-Pak (foam in place), Insta-Pak (expanding foam-packs) and similar "molded foam in place" systems can work well, when properly implemented.

IMPORTANT; DO NOT USE PAPER OF ANY KIND! Including but not limited to: news print, paper towels, rolls of paper towels, rolls of bathroom tissue, and etc.

DO NOT USE ANY HOUSEHOLD LINENS including but not limited to: No comforters, sleeping bags, pillows, quilts, cushions, bath towels, none of that stuff. It's simply inferior for packing heavy transceivers and provides ZERO crush-resistance G-force protection.

  • Box sealing tape: 2 to 3 mil minimum thickness by 2 or more inches in width.

  • *24 x 24 inch scrap cardboard sheet. Or 40 gallon plastic "leaf" bags for the packing foam-peanuts pillow method.


Plastic wrap or bubble-wrap the transceiver and pack it inside the smaller of the two boxes, purposefully leaving 2 to 3 inches between the face of the main tuning knob to the inner box's side. This is the important clearance, which will help prevent non-repairable shipping damage to the front panel embedded fragile soft-press-button switches circuit board. The top, bottom, sides, and rear panel clearance may be much less. The primary concern with this inner box is the transceiver's front panel and knob clearances. Use additional bubble-wrap or packing foam "peanuts" for void fill, tightly packing around the transceiver to avoid packing material settling in shipment. Before sealing the box closed with tape, mark the side of the box that the transceiver's front panel is facing for reference.

Prepare the outer box by partially filling with packing foam "peanuts" to a minimum depth of 2 to 3 inches. Place on top of that to form a false floor, either a sheet of cardboard or a couple of layers of bubble-wrap. Or use the plastic "leaf" bag pillow method.

Place the inner box inside the outer box aligning it on the false floor so that there is approximately equal clearance on three sides (2” minimum) and about twice as much clearance the side facing the FT-1000MP's front panel. Tightly stuff around the inner box's exterior with packing peanuts filling the void up to the top of the inner box. Add sheet of cardboard or a couple of layers of bubble-wrap and top off with packing peanuts, or place the second "leaf" bag packing "foam-peanut" pillow. Jiggle the outer box to settle the packing peanuts, compress the packing "peanuts" with your hands and stuff in additional material until no more will fit. Tape the box closed sealing all seams. 


All return shipping is normally done through FedEx's economical Ground Service, via my *FedEx account. For return shipping I charge the FedEx street price for shipping and insurance plus the following for packing labor:

$7.50 when shipping in your original factory box & packing; this fee is often waived for boxes that are in excellent condition.

$10 ~ $20 when shipping in your reusable non-factory boxes and packing, plus the cost of any additional materials as where needed.

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