Gaz, the Insulfoam is a pretty rugged foam insulation. You can stand on it and flex it quite a bit before it breaks.
I have used this same shipping method for the last three years now, the only problem I had was with casters that would sometimes get bent. Now I take the removable casters out, tape them into cardboard and put them in the Insulfoam packing or in the handles (two to a side).
This packing method has survived going to Australia, Japan, Norway, Finland, Germany, Switzerland, Canada and all over the USA. I don't use UPS, though, only Fedex or international shipping carriers (TNT Express, Concordia Freight, etc) that aren't clueless like UPS.
So the two inches on the front and back have never been a problem. You have three inches around each side, top and bottom with this box. If you're concerned you could get some thin plywood to put over the grill cloth, but I've never needed it. If a forklift prong is involved, it won't stop it anyway.
Taping all of the corners/edges is necessary IMO. That's just so the box slides and doesn't catch on a conveyor belt or another box so it can be hit by another box at an angle.
But past those considerations, this method has worked for hundreds of cabs.
Tips on shipping a 4x12?
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Re: Tips on shipping a 4x12?
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Re: Tips on shipping a 4x12?
Jim, thanks again for the sage advice. My concern wasn't about the intergrity of the packing itself, but rather the worse case scenario, and Fedex saying: 'Well, there was only 2" in the front and back, and we require 3"...'