Rough handling by a parcel delivery service can do more damage to your FI unit in 2 seconds than you will cause by driving it hard for thirty years. The best way to protect your FI system is to “double box” it yourself before shipping. Double boxing is not difficult or expensive; it just takes some additional time.

First, empty all the gas from the fuel meter by turning your unit on its side. Then pack the unit inside a cardboard box that fits fairly close around it on all sides. Ship the plenum mounted on the adapter manifold. A good box for this is sold by U-Haul Rental Centers. This box is 22″ x 15″ x 12″, and U-Haul calls it a “Legal Tote Box”. Fill the open spaces inside this box with bubble wrap or wadded up paper so your FI unit can’t move around. Do not put any Styrofoam packing peanuts inside the box with the unit.

Next, place the distributor (less cap) inside its own tightly fitting cardboard box. It’s very easy for the iron and steel distributor parts to nick and scratch the aluminum parts of your unit if you don’t put the distributor in its own box.

Now place the distributor and FI unit boxes inside a large box that will hold them both. The U-Haul size appropriate for this is 24″ x 24″ x 18″. It’s called an “Extra Large Box”. The two inner boxes should fit inside the outside box with at least an inch of open space on each side. Fill the open spaces between the inner boxes and outer box with Styrofoam packing peanuts.

Packing supplies such as cardboard boxes, bubble wrap, and packing peanuts are sold at almost all FedEx Office stores as well as U-Haul Moving Centers.

Personally, I prefer to use FedEx Ground. I’ve never had to file a damage claim with them, and their delivery times are usually no more than 3 or 4 days from anywhere in the continental U.S.