I have 24”x24” single layer sign I need to ship. How do you normally package a sign you can’t find a box for?
You make a box. Get a large moving box, break it down so it folds flat slip your sign in between the layers and tape the shiznit out of it.
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If you are worried about the sign being bent, you might consider slipping a piece of plywood in the packaging. As you can see, this sign made out of 16 gauge was not going to tolerate much abuse. I sandwiched it between two pieces of waferboard with spacers going thru the wood and the mounting holes of the sign. In that situation, the sign was floating between the two pieces of wood. I wrapped the sign first with wax paper and then a thin layer of foam wrap.
In either case you will be charged for a “non-standard” package. I shipped via PirateShip.com and it cost about $58 from Washington state to Oklahoma using UPS and got there in 4 days. It weighed about 23 pounds, I believe.
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If you or a friend have any leftover styrofoam wall board insulation, you can sandwich the sign and use cardboard outer skin. When taped really well, that styrofoam really helps with rigidity.
Another cheap idea is a small cradle/frame made from 1" by 1" pine that you can buy at any Lowes or Home Depot. Cheap and still fairly light. Cardboard outer cut from old Amazon boxes or whatever.
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I’m the minority here so take what I say with a grain of salt.
I don’t do signs, but if someone wants one enough I give them realistic expectations of shipping costs because I like to double/triple up to prevent any flex.
However, my last customer paid for and shipped me a box with foam so I could send him a sign I made.
I’m in CA and he’s in NY so…it was traveling quite a bit.
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I guess he really wanted that sign! Ya know, for a guy who “doesn’t make signs” you sure do make some nice ones and apparently have an appreciative customer base! 
Nah…
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Maybe no one in NY has a CNC table, so he figured if it can’t be done locally…what’s a few thousand miles across several states 
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All I can say is wow! you should teach a class
Ha nooooo way dude, there are significantly more talented people here than myself!
Only thing I will ever lay claim to is diagnosing these tables, which mostly anyone can do anyway.
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Thank y’all for the info I’ll be getting some foam and some plywood!
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This may help too…
Seth
P.S. Cardboard, like with most things being shipped, is never enough. Enjoy…
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