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If you want to use the free priority boxes, then the flat rates are a no no. The small one is too thin for this and the medium cost more than $11 to ship.
The only option I would use if the buyer request priority is the 6x6x6 cube box that you order online or get at the post office or a regional rate type A box but I am almost sure those can only be ordered online. These boxes are free but you need to request them way in advance and have them ready at home for when you get the orders. A regional type A costs between $5 to $9.88 to ship depending on distance traveled.
They kind of hide this option in the website and keep showing you the flat rate boxes first thus it took me more than 6 minutes to find it and could not edit the post above.
It seems like freebies don't get much thought when it comes to the logistics of packaging them, like the situation of the Hot Dog Stand bicycle poking holes in boxes. It'd be nice if Lego did actually pay attention to them instead of just taking the attitude that if the box lid closes, that's good enough.
*sits down on couch and grabs a beer and a bucket of popcorn*
Plus I was buying stuff to that value anyway, and will be again on Brick Friday. The way I look at it, I buy the sets I want, but I time my purchasing in order to get free sets that I want.
For example, a lot of people will have gone out and bought WVM as soon as it came out. Whereas I decided to wait until October when I'd get the free set as well.
And yes, I've had a few 'small box' sets this year and I do think the packaging for #40082 is more flimsy. Not really complaining, just noting.
This action will place you over the 13 ounce weight nearly every time, so shipping cost goes up. It is the difference between a prestine set arriving vs. possible damage.
I just know that one person I shipped to was slightly upset at the shipping cost at first, and then wrote me a "praise" letter for how well the set was packaged (protected) when it arrived.
I used to work at a USPS shipping center, and I package what I ship with "overkill" in mind, for I've seen how packages are "treated" at the sorting centers. Oh, side note from working at the sorting centers, the word Fragile on the box, for a person who works overnights at a sorting center, translates into finding out how fragile it really is :( In other words, reason I use bubble wrap with and fill the box with packaging over savings on shipping.
If we didn't put fragile tape on the item and it got broken, the buyer would complain that we hadn't used fragile tape...