We went wayyyy too big on the first batch and wasted a lot of tape. Â Ideal is about 4"deep, 22 Wide, 3' tall. Â have the top close with a seam in the center so you can stick a dowell through to hold the hanger. Think my cost on them is around a buck and a half - buck seventy five. That falls within limits for Fedex Ground so you don't get the oversized charge, for priority mail or express it would kill you. Â Figure $10 shipping, plus cost of materials.
Thanks for the help, Carlo. Unfortunately, I'm running a small-time operation here and it would be very impractical to custom-order boxes. Do you think the jacket would arrive okay if I first placed it in a large heavy plastic bag with tissue paper covering the jacket on each side (between the jacket and the plastic), folded it in half down the back seam, then folded it across the waist and placed it carefully in a large enough box (of course packing it full with tissue paper to avoid unnecessary shifting)?