Hello Everyone1,
Went to the post office, I asked for options and the most convenient way to ship within the US would be using their small priority mail boxes. If weigth is less than 1 lb. the cost is flat $3.85 anywhere in the US. This I had also verified here initially:
http://www.usps.com/consumers/domest...%20flat%20rate
I took two boards with me bubble wrapped, the weigth was 2.9 oz, each board then is about 1.5 oz. The post office employee suggested that I use cardboard layers between and outside the boards, then bubble wrap that bundle, which sounded like a great idea. With the cardboard layers, I estimate 8 - 10 boards will still be within 1 lb limit. Under 2 lbs, UPSP link above indicates the cost varies from $3.95 to $5.75 depending on zone.
The cardboards layers I can make from older boxes, but I have to buy enough bubble wrap. Instead of arbitrarily charging let's say $4.00 instead of $3.85, I'll purchase a bubble wrap roll, and will divide the cost by # of boards. This will be almost ludicrous, but so that we all pay exactly our total costs. Another thing: you all paid $5 per board for bill #1, but their cost eventually became $4.20, so all of you have a positive balance from bill #1.
Shipping from PCBNet to me was $20.0, that divided by 174 boards == $0.11 per board.
So for all of you in the US and with less than 10 boards ordered, I'll send Paypal payment requests for your Bill #2, the amount will be
[size=small]
Bill#2 = Rate + (0.11 + bubbleWrap/174)*#boards - (your positive balance from bill#1)
[/size]
The 10-12 board cases might be a little more if the bundles go above 1 lb, I'll let you guys know tomorrow.
For international addresses: One of you groupbuyers in Germany suggested to use the "Large Flat rate" USPS envelope, which has a flat rate of $9 if within 1 pound. I just checked
here and that rate applies also to Japan, Norway, and the UK. Canada's rate is $7. Using the small envelope rates go down to $5 and $4 respectively. Your bill#2 amount will be same formula as above, but rate will be your specific international rate.
Cheers,
Raul
PS. In fact, after applying the formula it turns out I owe some people money. Those who are in the US and ordered 6 or more boards have a positive balance from bill 1 larger than the final shipping charges. In those cases, instead of a payment request I will be sending you what I owe you.