Just an update. I have now successfully shipped about 15 boxes by this method. It is awesome! None have been returned and I have heard from all except 2 that they were received. This saves so much time AND you save about 40 cents per box postage. No more standing in line!
I pack the FRB, weigh (i use bathroom scales as it doesn't have to be accurate since Flat Rate is just that) go online and print the label w/postage, fill out the customs form (I haven't done this online yet) put the form in the clear pocket and attach all to the box and then drop them into the designated box at the post office. DONE! No lines, no tired feet, no bad moods....just a smile for serving my country by support the troops.
What I like best is that the USPS site has an address book where you can save all your addresses for your labels AND you payment info.......so you can just click away and print and you are done.