[ishani]

I'm prepping an Octane for a bit of a journey; beyond the usual of using a lot of packaging, sturdy containers for shipping -- is there anything people can recommend from a packaging and hardware perspective to help ensure it reaches its destination in good shape. 

I'm probably going to remove the PSU & wrap-and-package it separately as it makes the unit fit in the crate on its side, which leaves more space for foam encasement etc.

Any experienced shippers have any things to look out for..?

[roach-commuter]

I would suggest you remove the skins and ship them in a separate box too

[Raion]

Instapak Sealed Air is the best thing:

https://www.amazon.com/dp/B00NEFRFB0

I've shipped fully intact systems. Put one under the PSU bar as it expands so it doesn't break off, and then cover the bottom, sides, top and rear of the unit in it. It's expensive, but it works wonders to keep the unit in place. The alternative is lots of styrofoam and wrap.

Taking the skins off is not necessary.

You can ask Weblacky.

[ishani]

If my experiments with expanding-foam don't pay off, Instapak is a good shout, nice.

FWIW I'm building it into one of these - https://www.diy.com/departments/form-sky...505_BQ.prd - which should hopefully give a decent outer defence (plus it even has slightly crappy wheels to roll it around on)

Wish the bloody PSU handle was (easily) removable :S

[mopar5150]

If my experiments with expanding-foam don't pay off, Instapak is a good shout, nice.

FWIW I'm building it into one of these - https://www.diy.com/departments/form-sky...505_BQ.prd - which should hopefully give a decent outer defence (plus it even has slightly crappy wheels to roll it around on)

Wish the bloody PSU handle was (easily) removable :S

 I have had good luck using layers of 1" and 2" hard foam board that is normally used for home insulation. I usually tape a static bag over the entire rear of the Octane/Tezro for ESD protection and then cut a section(s) of the foam board to go around the PSU/ handles/and anything else sticking out. The idea is to get as much solid surface area covered with the board and then ship the item laying on its back. then I bubblewrap around the sides and over the face so it all stays together as a "block". Then put this into a box and use the same foam board to create a box around the machine and then a top piece as well. 
 The idea is to spread the impact load to as large an area as possible to prevent any one spot taking the full hit.

 I have shipped 75+ systems like this with zero breakage.