To summarize what I do and have found to work best, easiest and usually the most cost effective way FOR US SHIPPING:
The key really is to ship 1st class under 13oz in poly bags and everything over 13oz goes in a Legal Flat Rate Envelope (if it fits) or into a Regional Rate Box A (or Box B if needed), except shoes. Best prices are though ebay if you are a Top Rated Seller, etc etc. I never use USPS.com even when shipping to SF members.
Single Tie: Folded in 1/3's. Large tip gets folded in first to protect it. Put inside "tyvek" then inside an "envelope" then inside a poly bag to ship.Should be about 6 oz and $2.03 off the top of my head 1st class.
Multiple Ties: Same, each gets it's own "tyvek" then all placed in "envelope" then envelope goes in poly bag (under 13oz). 4 or 5 ties, prob best to ship in a USPS Flat Rate Envelope for $4.99
Shirt: Folded into a "tyvek" then into a poly bag. Usually 11, 12 or 13 oz depending on size and material.
Multiple shirts: Each gets it's own "tyvek". I fold these one extra time in half, and can usually get them into a Legal Flat Rate Envelope for $4.99. 3 or more shirts go into a Regional Rate Box A
Pants: Folded in half twice the long way, then folded in half the opp. way. shoved into a "tyvek" then into a Legal Flat Rate Envelope. Good idea to extra tape these close (Priority Tape is FREE) as this is a tight fit into the envelope, but better then using a box.
Multiple Pants: Same as above, but Regional Rate A or see "Heavy Coat" below.
Sports Coat: tyvek then Regional Rate Box A
Suit: Coat and Pants get seperate tyvek then both go into Regional Rate Box A. If too thick see "Heavy Coat" below.
Heavy Coat: tyvek if it fits (prob wont fit) then into Regional Rate Box B or Medium Flat Rate Box depending on distance. Save a buck or two cross country with Medium Flat Rate (NJ to CA)
Shoes: USPS Shoe Box
This keeps your supplies very limited. Yes you might get an odd ball here and there but this covers about 95% of what you ship. I keep different size boxes (all Regional Rate A1, A2, B1, B2 + Small, Medium & Large Flat Rate) but I have an office which I have plenty of room.
INTERNATIONAL SHIPPING - Try to keep it under 4 lbs (1st class international rate) and send it 1st class registered OR just charge enough, use Priority Boxes + a scale (cheaper then the flat rate boxes for clothing weights usually), insure it though ebay and cross your fingers. If it dosent arrive, just send a refund and file a claim.
This is amazing and truly appreciated, I printed it out and placed it in my "office" (the tiny corner my wife allows me in her arts & crafts room).
Just a little confused on definitions "Put inside "tyvek" then inside an "envelope" then inside a poly bag to ship"
So the poly bag I get, I purchased some from ebay that you recommended. Are you saying you put a tie into 3 different envelopes?
Tie goes in Tyvek Envelope
Than in plain envelope
Than finally into Poly Envelope
Sizes not representative of course, but damn that is a lot of wrapping.
Also you said "(Priority Tape is FREE)", where would you get this? I don't see it on USPS.com to order.