Originally Posted by Daedalus66
How about protecting the pins by using Styrofoam on that side of the board and wrapping some masking tape around the board/foam bundle, then shipping in bubble wrap?
Yes like this. You only need some Styrofoam of some kind that is a few mm thick. This would prevent damage in all but the worst circumstances (that angry postal worker that decides running it over if FUN!) You could then use the same packaging that you already do.