Nathan, I was pulling your chain. I got a good laugh out of that cat's ass comment, I hope you did too.
The fat pig's ass crack (pun intended) was pretty funny too. Nice work ChairGuy.
Your drawing looks good (the artist in you) but it is a bit over simplified.
Your missing the top and bottom foam pieces and all of the foam pieces would not be the same thickness. It would be dependent on the outer box size compared to the inner box size.
At Buffalo Electronics we ship 20,000 LBs of products per year, all in boxes around this size, we use peanuts because they work and are easy to use.
BTW we use the green anti-static type of foam peanuts, they cost more but they are the best and are very easy to work with unless your pissed off.
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For those wondering about the tour packaging:
The Purist comes in its own box with four pieces of custom fit foam, it is perfectly protected on all sides, the power cord is in a pocket cut into the foam. This is our standard Purist packaging.
The outer box (we double box to keep the Purist box in new condition) is whatever box we have that's slightly bigger than the Purist box.
The outer box does get roughed up from shipping and needs to be changed every so often (maybe every 7-8 auditions from our recent experience) with whatever box is readily available at that location.
A replacement box can and usually will vary in size (from the original BE used) so the fill needs to be more flexible than fixed size pieces. This way the exact outer box size becomes less important and easier to find.
With a 23 LB box that has a 250 sq. in bottom area, it calculates out to 9/100 ths of a LB per sq. in. This is a perfect application for using foam peanuts as fill.
Some peanuts should be put in the outer box first then the Purist box inserted then the rest of the peanuts around the edges of the Purist box and on top of the Purist box. The Purist should roughly be in the middle of the outer box.
If a few peanuts get lost or compressed and the packaging seems loose, we recommend using wadded up newspaper inserted here and there to tighten the fit.
This is simple packaging that can be repaired or adjusted by anyone.
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Nathan, I do understand trying to find a better way and thanks for the suggestion but I hope you now know why we went the way we did.
A better choice might be custom molding (like nOrh ships its speakers) the fill between the inner and outer box but then if the box needs to be changed were back to square one. All things considered I prefer the peanuts for their flexibility.
Putting the packaging design aside for a minute, it does seem that you should not have removed the peanuts without having something else to take their place. The important issue was protecting the Purist.
Now that everyone understands the packaging we are using and why, we might be in good shape for the rest of the audition tour
Monday the Purist goes to ptn in Oregon then its down the west coast.
