Making Custom Boxes

Over the years we’ve worked on hundred of stereos from all over the globe and one thing we’ve learned not to underestimate is the stress that shipping boxes go through. Whether it’s traveling 50 miles or 5,000, accidents happen and it’s incredibly important that the box be able to absorb shocks and falls while keeping the stereo inside safe.

To that end, we’ve come up with a box design that we’re very confident in. We’ve never had any stereos damaged when using these boxes, and highly recommend that they be used when sending your stereos to us. We’ve put together a step-by-step tutorial on how we make these boxes below. For more information, or to order a box, please contact us at tech@qrxrestore.com. We’ll need to know the model you’re shipping us and your address. We will then invoice you via PayPal.

Step One: Cutting The Foam

Using a Variac transformer to heat toaster wire in a plywood frame, we cut the foam pieces that will be used on the top, bottom and sides of the inner box.

It takes a lot of cutting to get all of the pieces we need

Step Two: Assembling The Outer Box

We use a heavy duty, double walled 30″x24″x12″ box.

Step Three: Inserting the Foam

We then put a 30″x24″x2″ cut piece of foam in the bottom of the outer box.

Then, four 8″x24″x2″ pieces of foam for the sides

Followed by four 8″x24″x1″ side pieces

Step Four: Assembling The Inner Box

We use a single wall 24x18x8 box for the inner box.

Step Five: Final Foam Pieces

Depending on the model of receiver the box will be used for, we add a bottom piece of foam to the bottom of the inner box. This is measured to fit the feet of the receiver to help hold it in place and further absorb shocks.

Next we put either a receiver or, if we’re sending an empty box out, bubble wrap inside of the inner box and close it. If we’re sending a receiver in the box, we wrap the unit in bubble wrap held on with saran wrap. We don’t use tape as it can do cosmetic damage to the cabinet and face plate. If you must use tape when shipping it to us we recommend you use painters tape. We then insert a final 24″x30″x2″ piece of foam on top of the inner box.

Step Six: Closing and Shipping

Now we close and tape the outer box, add “Fragile” stickers to all sides and it’s ready to be shipped out.

For more information, or to order a box, please contact us at tech@qrxrestore.com.
We’ll need to know the model you’re shipping us and your address. We will then invoice you via PayPal.