How to make a cheap impact resistant shipping box

I have had a couple of products damaged in shipping, and by the time I have jumped through all the hoops to claim the insurance, it wasn't worth it. Its better to just keep the damage from happening in the first place. This is especially true for an international shipment like this one. I need a better shipping container - but it has to be affordable. In this video I use a $3.50 can of Great Stuff expanding foam and a couple of Cardboard Boxes to create a double wall impact resistant shipping container. No more getting expensive stuff damaged in the mail for me!
My first experiments using "Great stuff" to make custom packaging were over 20 years ago. I sprayed the foam into a plastic bag, and then "molded" it around what I was shipping. This worked, but required several cans to get anywhere. Last night, I had to pack another box, and I went to Lowes to get foam board for padding. Sticker shock: its past $30 a sheet. Suddenly, a scheme to use that extra can of spray foam I had in the basement popped into my head. The intro/close picture is the concept, and the video was my first attempt to build it. It worked very well for me. See if it works for you.

[@MsDabree]

Too messy. Just use sheet insulation

[@ernestocelorrio7440]

✌😁