How to Build a Solid Stained Glass Shipping Box

To ship a piece of glass, it must be packed and well protected. We build a box around each piece of glass that we ship. It should be a custom fit so the glass can be properly protected. The images that accompany the article are of us building a box for an 18″ by 30″ window. We use the same techniques when creating larger windows.

We start by laying down a piece of 1″ thick rigid foam insulation that can be purchased at a home improvement center.

We then place the piece of stained glass to be shipped on top of the foam. I line up two sides of the glass with the edges of the foam.

Using a utility knife, I score the foam along the two edges of the foam that need to be trimmed.

Next, I break the foam at the score line by lining up the score on the edge of the table and pressing both ends firmly. It really does make a popping sound that will scare the cat or any small children in the area.

I then line up the resized insulation and cut out an identical piece using the cut foam as a template. While I’m cutting foam, I cut several strips the width of a two by four.

Here we have the “sandwich of foam, glass, foam, ready to create some wood”.

Here is the “sandwich” and two of the 2 x 4 size foam pieces for the edges.

I place the foam edges around the sandwich so I can take the measurements of the 2 x 4s I need.

Here you can see the sandwich, surrounded by foam and 2 x 4’s

I remove the top layer of foam, so you can see what’s going on in relation to the stained glass window.

I use pipe clamps to gently tighten the frame. The 2 x 4’s only put a slight pressure on the foam holding the glass.

Now that the boards are aligned, the box is ready to be assembled. I put a layer of “soft” foam under the panel and on top before replacing the top layer of foam. This way there will be a small amount of sag when the panel is shipped.

With pipe clamps holding the wood frame together, I use additional clamps to tighten the side boards so they line up perfectly. This puts slight pressure on the glass so it will sink slightly into the foam and stay securely attached as it is shipped.

I drive a couple of finishing nails into the frame to hold things together. There is little danger of hitting the glass since it is very far from the edge of the case. So I can remove the pipe clamps. No need to drive many nails, just two per joint, the side will hold the box together.

I fill the void at the top of the box with Styrofoam scraps that other carriers send me.

Then I cover it with another layer of foam sheet. I want there to be a little bit of pressure in the box to keep things from having too much play.

I put an instruction sheet inside the box.
TO UNPACK YOUR GLASS SAFELY,
FIRST REMOVE THE FOAM 1″ WIDE FROM THE EDGES ON ONE SIDE AND THEN FROM THE TOP OR BOTTOM. THIS WILL FREE UP THE FLAT FOAM SO YOU CAN LIFT IT UP AND EXPOSE THE GLASS.
TURN THE GLASS CAREFULLY AND SLOWLY. THE GLASS HAS LITTLE STRENGTH WHEN IT IS FLAT.
ONCE THE GLASS IS VERTICAL, YOU CAN TAKE IT ANYWHERE YOU WANT AND HANG IT ON THE CHAINS BY THE RINGS PROVIDED.

I then mark the foam pieces to remove first mentioned in the unpacking instructions.

I then cut plywood to the size of the frame. Two pieces are needed.

I lay the top over the side as instructed, lower it into place and line it up with the frame.

Then I screw 1″ long drywall screws around the top to hold it down.

I pick up the box and tilt it gently, making sure to hold onto the exposed foam on the bottom to keep it from shifting.

With the bottom of the box facing up and the foam side exposed, I’m ready to attach the bottom plywood.

I put it in place and line it up.

Then use staples to hold it in place. I do this because I want it to be easy to remove the top of the box and hard to remove the bottom. That way, the client who receives the case will have a higher chance of success.

I write instructions on both sides of the box, like, NO STEP, GLASS FRAGILE, and DO NOT LAY IT FLAT. At the top, I add arrows and the words: “Remove the screws on this side and read the instructions.”

Then I take the box to the UPS store and hope they don’t drop it or drop it too hard. I figure if the driver doesn’t pull it sideways and uses it to step over once or twice, it will survive the ride.

So I’m insuring it for retail value!

I received an email from Debra Beatty who followed these instructions in sending a window to Grenada from California via US Postmaster Ground and it arrived safely. But I have had times where customers got their windows with a small tear, I think those times were because the gasket was so tight it wouldn’t give.

I took several photos to illustrate what I am talking about in this article. You don’t have to see them, but if you want to go to our betterstainedglass site and read this article