I have some experience in this area and can offer the following information. First, I am in the Northeast and it seems most of the people I sell bikes to are always on the west coast. This is probably the worst case scenario for a domestic shipment inside the lower 48. Now I have used UPS, FedX and the USPS and here is what I find.
UPS rates keep climbing and like was mentioned before most bike boxes get rated as oversized 2. This carries an automatic 70 pound rate no matter if the box has 10 pounds inside. This can be an expensive proposition if you are selling frames alone. Service wise they are fine, you can track your shipment on line, have them estimate a delivery date and it always seems to work out. Another beef, the rate calculator web site I use at home is not very good at calculating the oversized stuff and you can get caught off guard when you bring it to the counter.
FedX, I have tried them recently at a customers request and find them equal service wise to UPS but for some reason in my location they will not carry change. This means you have to have the exact amount of money that they will charge or you leave change on the table. This has happened to me twice before I figured out what was going on. Rates seem to be less than UPS so far but not by much. They also can calculate delivery pretty well. Their rate calculator on line is also not very good at estimating. I find that their system is pretty old fashioned as I have to fill out a paper form longhand with a lot of useless information before I submit the box for shipment. UPS has this computerized and all you do is key in the customers name and address and it takes care of the rest. You print a label and take it to the counter.
USPS, I have used the Post Office for frames and smaller bikes and even once shipped a bike to Japan in two boxes and here is why. The USPS will only take a box with the combined lenth and girth of 108 inches. This is the size of a BMX box. Any larger and they will reject it. If you can get your bike or frame into this size box you can save a bundle about half of what UPS or FedX charges. My shipment to Japan saved the customer about $400, no kidding. I broke the bike up into the frame and some parts and the wheels and some parts. Shipped it surface which took over a month in transit but the customer was willing to wait for the savings. Both boxes arrived and the total shipping cost was just under $90 to Japan.
I offer this information just as a guideline but it has also caused me to re-think selling a complete bike. I hate to admit it but selling a bike broken up brings in more money from ebay and shipping is more reasonable with a lot less hassles. I have been hit with a couple of complaints about shipping cost for a bike and my reply is to have the prospective buyer pick a carrier and set up the shipping on their end. Quite soon they come back and just pay the original transportation cost that I asked for once they find out on their own what it really costs. Remember, cusotmers can arrange a for a shipping tag with a carrier so they pay the actual cost and all you have to do is deliver the box addressed.
Some tips. Here in the NE I have no problem with getting bicycle boxes. I visit several bike shops and they are all to willing to let me have more than I can take. I am often surprised at postings I see from the west coast where bike shops charge for a box (nonsense). I have one bike shop that I do a lot of business with, we have become personal friends. He saves me all packing materials that he takes off new bikes that he build up. I get the frame wrap, fork inserts, plastic axle flanges and small parts boxes all for free. Also where I work I have access to the re-cycle bins for old packing materials. I get all the bubble wrap, foam and packing peanuts for free that I would ever want. Check out these possibilities and save youself and your customers a few bucks.
Ray Homiski
Elizabeth, NJ