You are not allowed to use USPS flat rate boxes. They are property of the post office and are intended to be used for their services. Home depot has great boxes fairly cheap. I think you can get their medium box for about 70 cents.
And Capital Recovery, you will save money if you keep those boxes to just 69 pounds. There is a surcharge added by Fedex and UPS once that box hits 70 pounds.
It shouldn't take you long to create a pallet by the sounds of it.
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