The trick is getting the length-width-girth total of the package to less than 165 inches (and no more than 108 inches in length). If you can do that you avoid that big jump in price for oversize package.
When I bought a set of Pentex sails from EP they shipped them in a long box created from two long narrow boxes. If you nest two 10 inch x 48 inch boxes using the flaps you can end up with a 108 + 10 + 10 + 10 + 10 = 148 inches, even a 12 inch box would still be 156 inches.
Create the box, then print your own UPS label from their online service and drop it off at the UPS store for the best overall price.
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Damon Linkous
1992 Hobie 18
Memphis, TN
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