When shipping an engine back to a manufacturer to be repaired how do you package it? In my case I have the original box and the original outer shipping carton. Is that enough? Or should I get a larger box with bubble wrap and/or those foam peanuts and place the engine in its original box into the larger box?
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"More " is always better Greg, but I've generally had success with the original manufacturers inner & outer packaging.
Depends on how lucky you feel. Most times, the original shipping carton will do the trick, but obviously the extra padding offers an extra margin of safety. You do need to remember to put all the little foam and cardboard inserts back in to protect the engine from being banged around as well.
I've shipped my loco back the same way I recieved it in the brown shipping carton. Adding an extra box is probably not a bad idea however, I don't know that the service department will return it that way.
get a larger box with bubble wrap and/or those foam peanuts and place the engine in its original box into the larger box?
Yes, like that!
i have alwys used [mny times] the original box the engine is packged in with the foam core and the original outer shipping carton. Never a problem.
This is with both die-cast and 3rd Rail and WEAVER brass engines.
Good luck with your shipment
I think if you inquire with the shipping company when you purchase insurance, they require something like 3 inches of the "peanuts" packaging material on all sides(or they can claim you did not properly package it and deny any claim). While I've never tried to collect on insurance, I hear from others it can be a nightmare even if you do meet all the little rules most people never think about.
Most (all?) engine shipping boxes don't have 3 inches of styrofoam in all directions. So if a fork lift punctured 2 inches into your box and skewered your item, they would deny you a claim because you didn't have 3 inches of protection.
That said, I'm not sure I've ever had a company return something with that same level of over packing, even if I sent something to them with the added protection in a manner that it would be re-usable for the return trip.
-Dave
All of my locomotives have survived the trip across the Atlantic, at the mercy of the postal services, packed only in the original packing and outer carton. But Lionel do make excellent packing boxes. 
Unfortunately!
The words: 'Fragile' and 'Handle With Care' means......!
RJL
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