PACKING INSTRUCTIONS

1). The Bottle
For large-necked bottles.
Stand the bottle on end and carefully fill, kernel by kernel, with plain popcorn (not salted or buttered). This is sometimes sold, pre-popped as a packaging material. Enviro- Foam is one of the trademarks. However the product can easily be made using a popcorn popper or a paper bag in a microwave. Just make sure no grease is present as this will stain the sails. Remember to tie the bag shut if you use a microwave and do not use a metal clip or tie.

Allow the popcorn to settle softly around the ship. Tapping the bottle gently against the hand will help. The trick here is to use the popcorn as a packing without damaging the ship further so a gentle touch is required. Once full, leave the popcorn protruding slightly from the bottle and screw the lid back on.

Please note: Styrofoam is not recommended for this as it is very difficult to remove once it is in the bottle due to the adhering properties of the Styrofoam. Rice, pasta, or other food products are not recommended either as they leave dust inside the bottle which is very difficult to remove.

For small-necked bottles.
Should popcorn not be usable ( If the neck is too small to install popcorn easily), the only other product I can recommend is flax seed. This is easily available from most healthfood stores. It pours easily. There is minimal dust. And it does not adhere to the ship or the bottle. Simply fill the bottle and replace the cap or stopper.

1-b). IF The Bottle is Broken:
If , however, the bottle is broken, and the ship is outside the bottle, you will have to proceed differently.

Make a three sided a-frame “tent” out of heavy corrugated cardboard. Tape or otherwise tie the ship’s hull to the bottom of the “A”, tape the “A” together and wrap securely in several layers of bubble wrap. Pack this inside a larger box with Styrofoam peanuts. Loose pieces should be packed with cotton wool (so they do not rattle and be damaged in shipment) inside a small box, plastic bottle (35 mm film canisters are ideal) and enclosed inside the box with the Styrofoam peanuts - not inside the “A” frame where they can damage the ship.

Please do not include the broken bottle. However, it will greatly help if the basic dimensions of the bottle are noted on a piece of paper and included with the ship. These include the outside diameter, the length of the largest section of the bottle (not including the neck) and the inside diameter of the neck at it’s narrowest point.

1-c). IF The Bottle neck is Broken:
If , the bottle neck is broken off and the ship is still inside, PLEASE, DO NOT ATTEMPT TO REMOVE IT. Please, leave that for me. Pack the bottle with popcorn or flaxseed as above and apply several layers of wide cello or duct tape across the broken neck opening to keep the popcorn/flaxseed in place.

2). Wrapping the bottle
Next, tightly roll the bottle in several layers of 3/8” diameter polyethylene bubble wrap. Larger or smaller diameter bubbles are not recommended as they do not provide the desired amount of protection. Secure this with tape and fold the ends over, securing these with packing tape lengthwise around the bottle.

3). Packing the ship
Pack the bubble-wrapped ship in a secure thick-walled, cardboard carton with at least 4 - 5” of solid-packed Styrofoam peanut material surrounding the bubble wrapped bottle. Important: Do not leave an air-gap within the carton. It is imperative that the bottle should not be able to move inside the carton. Remember that shippers, despite their assurances, routinely toss cartons many feet (even those clearly marked Glass - Fragile), so extreme packing measures are called for.

The addition of a second layer of cardboard inside the top and bottom of the box is highly recommended. Any separate parts, may be wrapped in soft paper toweling in a plastic bag and enclosed within the Styrofoam peanuts. Securely fasten the carton shut with packing tape and/or a strong adhesive. If the ship has a separate stand, do not send this as this may act as a battering ram during transit, breaking the glass.

4). Customs declaration.
THIS IS MOST IMPORTANT
Proper documentation is most important. These guidelines have been developed with Canada Customs to ensure prompt processing of your ship.

1. A standard, full sized customs declaration (white, not the small green one) is required for any shipments coming into Canada.

2. Please, fill this out completely with the following notation:
“Ship in a bottle being sent for repair. To be returned to owner (sender) upon completion of repairs.”

3. Also tape an envelope onto the outside of the box, containing a photocopy of my quote and mark this envelope ”Ship in Bottle for Repair - Customs Documentation Enclosed”.

Please Note: Failure to provide the proper customs declaration and documentation will mean that Canada Customs will charge 15% Canadian Sales Tax on the insured value of the ship and this will be passed on to the sender. This may be recovered, but it is a long and involved process.

5). Shipping.
Recommended shipping is via USPS International Air Parcel Post - Not Expedited Mail - insured against loss. Also Note: No carrier - Post Office, or otherwise - will insure glass against breakage (only against loss) which is why you must pack the ship securely. Major couriers are not recommended, unless you are willing to underwrite the additional brokerage fees and taxes that all courier companies charge for processing cross-border shipments. Canada Post will broker it at no charge as long as your insured value is less than $700 US.

David Smith
April 2000

dsresrch@mail.com