Hello Mr Killgore - about box size, cost etc. There used to be a surcharge if the box exceeds a certain size. Haven't sent one of those in a while. 'A certain size' means total wideth length and girth exceeding a certain number of inches. 100 and some. If u search the USPS site u should be able to find it. I have paid it once or twice in the past when I shipped good quality wooden hangars and other things to units that asked for them - for men's pants/suits - etc taht wouldn'tfit in anything the PO had to offer. Anyway, u might want to check before u get to the PO and are surprised with the shipping weight plus a surcharge.
I have sent seven or eight large video boxes packed with a surprising number of items including rolled Ts and socks as well as other items in one 12 x 12 USPS box and also multiple video boxes in the large FRB. There are several size video boxes available thru the PO - all for free. Buying items in bulk can save u a lot when you send individual boxes for each member of a unit. I had one contact that I supported this way thru his entire deployment. One month I'd send food another month hygiene gear. It gets pretty expensive if u don't buy bulk - meaning large boxes of pop tarts, snack bars, bags of candy, etc or hygiene items - all availabel at the discount places like BJ's, Sam's Costco's Party Stores etc. If you put the same thing in each box it also helps a lot in filling out the customs form - ie: 8 deoderants, 8 toothpastes, etc:). Then I'd tape a card addressed to each Soldier on top of each video box.
Hope this helps. Don't forget the Craft stores where u can get packs of cards for a $1.00 a pac sometimes 2 for a $1.00. And all sorts of other toys for $1.00 a piece. Although a $1.00 apiece adds up fast when u r buying for lots of people.
Have fun - u may be getting lots of mail. Don't forget to include some Any Soldier postcards and pens:).
Ann
PS Forgot to mention - I've also used those plastic pencil boxes they sell for 50 cents or a dollar when school supplies go on sale. A regular size bag of coffee fits in there really nicely. So cigars, drink mix, etc etc and everything stays nice and fresh. If you find ones with handles, they make great boxes to take to the shower:).