So I buy a Kawasaki FE290 golf cart engine over the summer, along with a muffler and 2 carbs. All of that is easily 70 pounds, probably more. This is how the ass clown ships it – single ply cardboard box with a few pieces of foam. Here they are in order of un-boxing the engine:
I wish I could say I made this up, but this is exactly how it looked when I opened the box!
Nice how the carb and oil filter are right next to the side of the box.
Wonder how that could have happened?
Another nice touch – no significant packing between the clutch (which is attached to the crank) and the side of the box.
After many emails back and forth, I got 1/2 of my money refunded. The guy kept blaming UPS not handling the box carefully enough. Simply amazing!
So this is how I box up an engine. Remove all the parts that stick out or can be easily bent up:
Plug up all openings:
Using a heavy duty, doubly wall box:
Cut-up 3-4 pieces of cardboard and put them in the bottom:
Bag the engine:
Now the time consuming part, cutting up pieces of cardboard and fitting them around the engine to pack it in tightly:
With the crank side, I cut out holes in the cardboard to slip over the exposed crankshaft. That puts any pressure on the side of the engine and not the end of the crank:
The engine is in there nice and tight:
59 minutes later I’m finally done, box weighed in at 79 pounds. Next time I am going to use expanding foam. That should save a lot of time and weight.