Shipping and Crating 101 From My Perspective:
By Eric Humes

I have sold my airplane after spending several years building it to the point of ready to cover. My intentions were to get it crated up securely so that it reaches its destination, in my case over 8000 miles. To start with, keeping the crate/container under 144" is a key factor in shipping costs. Shippers, that is LTL shippers, (less than truckload) quote a rate one of two ways. The first way is based on size of object or item under 144". The other way is if over 144" in length. In my case, if I could keep it under 144" in length and use my location and destination (Miami FL for this example) it would have cost me under $300.00. My problem was I was about 149" and that gets quoted bulk rate based on volume. I never got an answer on width and height, nor weight that made much of a difference in price. But keep in mind that trailers are approximately 90" wide inside the back doors (or sides) and the height is less than 108".

While I was asking for my rate, I gave multiple widths of possible crates up to 7' wide and didn't notice any difference in price for containers under 144" long. Since I was over 144" long, my rate, based on volume, turned out to be about $1200.00. WOW, what a difference! So I asked the shipping broker if he thought that just by being over a few inches without being heavy (my case about 800 pounds), if he would ask the shippers for a better rate. Seems the LTL world is very common and they base their loads (LTL's) on getting four of them on the same trailer. Seems to make sense as they want to fill it up and make more money. The law of averages says they are not going to get four 144" crates every time and some of them may be under 144", which is where a little persistence pays off. I am flexible with my shipping dates and I also have a dock, as well as a forklift, at my company. These are things that I have come to take for granted. Anyway, my new rate for shipping to Miami, FL was about $400.00 picked up here at my building. I will include below a company and contact as well for stateside shipping. They were very easy to deal with; I talked to a real person and their follow up has been great. I did not tell them what was really in the crate! I only implied that it was similar to the trailer mounted pressure washers that we always ship.

I am very comfortable with metal fabrication work and that is why I chose metal for my crate framework. There is a second reason in the fact that other countries require anything shipped to them be of processed wood products for termite and other pest import problems. I measured very carefully the main components of my kit and I wish I had made my crate a little wider, but I got the job done quite well and secure with size of my container. I took some time to do a basic drawing of how I thought I would lay out my items.  

Starting with the fuselage, I measured for mounting points that would coincide with the standards of measure of raw materials, 2x4x?? and 4x8 sheet products, and 12 to 20 foot long steel. After measuring, I needed a crate 50" wide X 62" tall and 149" long. I chose 1-1/2 x 1-1/2 x 1/8 angle iron as my frame components because of ease of drilling through for the self tapping screws to hold the sheeting on. I put my cross bracing in at corresponding locations/intersections of mounting points, keeping in mind the basic material dimensions of raw materials. I wanted to have all of the welding done prior to taking the crate home for the insertion of the goods. I mounted the fuselage first, centered and secured, then proceeded to measure, measure, and measure again for all of the other items. Even with all of my building and fabricating years and projects, I would have liked to have had a couple more inches in width. All of the small items that seem so small and insignificant WILL add up. I filled every nook and cranny with the smaller items. I used 3 rolls of strapping tape for as many uses that you can dream of. Another product that you MUST get is self stick foam rubber. I would not have been able to secure these parts without it. I used it on the leading edges of the wings, the ailerons, struts, etc etc. I also used rubber mountings for my wing trailing edges and fabricated custom fixtures to hold the wing leading edges, the fuselage, the engine, and the tail group. While laying out my crate, I also wanted to secure the engine for shipping in its original crate. I again measured and determined it would fit over the front of the fuselage, but needed a strong mount to carry the box. Again, a great place to put all those odds and ends in with the engine.  

The next big items to get placed in the crate were the wings. Mounts were made, secured, and padded. Strength and security is key. Most crates and boxes I get here at my business have some kind of rash on them and I am sure they get bounced and beat up. Another thing to keep in mind is C.G. of the completed crate. My example ended up being very near the middle of the crate. This takes some design calculations as well as luck. You might even decide to make 2 separate crates and join them together for an easier time packing. I almost did this. Next in were the struts, the roll of covering, and the ailerons. Long items were planned for and secured using custom mounts. Another item you need is wire ties. I have and use 14" long 200 pound test ones here at work and they came in very handy as well. The engine mount was screwed to the floor of the crate, and moved 3 times to make just a little more usable room. Next in was the landing gear, tail feathers, covering supplies, radiator, boxes of parts, etc etc. I clecoed the glass back on the fuselage for security which turned out to be a good idea. Fifty or so clecos go with the kit and the parts get there in the same good condition I would want them in.  

I guess as I go along here, the main goal was security for the kit. I made a deal with a person in good faith and want them to be very satisfied with how the components are received. I spent about 60 plus hours on the crating of the kit. I took pictures of the adventure for memories as well as representing to my customer what was in fact in the box. I also did another thing. I have access to a banding machine and made sure the crate, after screwing all the sides down, had every seam banded to prevent the crate from being tampered with prior to arrival at its destination. This also helped secure the sides for rough handling during transport, as well as secured the skids mounted to the bottom of the crate.  Another big challenge for most is the loading and transport of the crate to the shipper. Mine turned out to weigh about 800 pounds. We have the equipment to handle this but most people don't. Your local landscaper usually has a skid steer (bobcat) with a set of forks for loading if you don't know anyone with a forklift, or Switch-N-Go, or car hauler.   

What I learned: Just like building an airplane, a house, a building, or anything else, preplanning was key. Choose components that will do the job well, work within your abilities, ask anytime you need help, and don't rush into this. Expect the unexpected. As my selling/shipping story unfolded, my original purchaser, located in Amsterdam did not purchase my kit. I had lots of interest on my kit, so I was not too unhappy. The shipping costs to Amsterdam and/or Germany were actually very reasonable. I got two quotes, one by air and one by ship.  $1800 by air freight and $1300 by ship.  I do not have the final dollar amount to go from U.S. Miami to Argentina where my kit will be going as that is not part of my deal, but Intl Freight forwarders will get you that.  I never thought that I would sell my kit. Where have I heard that before? (Mark?) I am looking forward to starting my new one and will keep anything that comes with it for possible future transport. You never know!  Feel free to e-mail me with questions or just to B.S. airplanes.

Eric Humes
p u s h n p u l l  (a t) c o m c a s t  (d o t)  n e t

USEFUL INFO:

International Shipping: