Originally Posted by chops

ive shipped a few headlights in my day. heres what i do:

- wrap em in newspaper
- create triangle reinforcements out of cardboard to tape around the brackets (this is so WHEN the box is dropped and thrown, if it lands on a bracket, you dont want it breaking)
- tape some triangles to the lens as well
- bubble wrap the entire thing
- individually boxed

tip: package anything you ship in a manner that it will not break if the box was thrown 5-10 feet away, and will survive a 5 feet drop. i worked at fedex for a few years in college....and a package needs to get across the USA in anywhere from overnight to 3-4 days. boxes are not picked up and lightly set down. i always throw my own packages that i ship out just to be sure itll survive my hands before i hand it over to the shipping company