Originally Posted by harveyc

Maybe I'll do a little video or photo series of this tomorrow or early next week. By just cutting off the ends you can add together two boxes as is and you end up with a box that's about 6" x 8" x around 36"-40", but it's best to keep it under 1 cubic foot to safe on postage so I usually take off about 2" along the length on one side on my table saw (I often prepare many boxes at one time like this so that I have some for future use and this will give me a box that is 6" square so it's still under a cubic foot even if it's 40" long. I create new end flaps out of other boxes (usually use the box referred to as a "shirt box"). I've shipped maybe 100 chestnut roasters in such boxes and have sometimes got a funny look from someone at the Post Office as they wonder if a new box style has been introduced.