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Did you follow the paper tape "rules"? I saw somewhere on reddit you need to tape every seam with paper tape. My warehouse uses those but I cant find any info on it, I think I'll just tape the hell out of it
I am just going to declare it as a rifle lower, that's technically accurate and what would be on my sales receipt
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The proper paper security tape needs to be used to mail via USPS Registered Mail. Every seam of the package must be covered and the post office will stamp all of the seams with a red stamp to show its not tampered with.
https://faq.usps.com/s/article/How-do-I-Send-a-Mailpiece-Using-Registered-Mail-ServiceThe package should be sealed with glue, plain paper tape, or cloth tape. The tape must be able to absorb ink and must visibly damage the envelope or wrapper if removed. In addition, the mailpiece must bear the complete names and addresses of both the sender and recipient.
Regular plastic based packing tape can't absorb the ink stamp and will/should be turned away by the post office employee.
This is the tape you need.
http://www.postalproducts.com/product/N1024700.htm
It has to be wetted with a sponge to activate the glue and then applied to the package and the glue allowed to dry. I have used it for years and its a bit cumbersome but you get used to it over time. The key is to make sure you cut the tape to length before you use the wet sponge to activate the glue.
As to "legality" it has been debated endlessly whether machinegun receiver is "concealable" and/or would be legal for a non-licensee to mail via USPS. (There are numerous threads online discussing if a stripped or upper-less M16 or AR15 lowers are legally mailable by a non-licensee with no definitive written guidance from the post office.)
You can read the USPS regs for yourself here.
https://pe.usps.com/text/pub52/pub52c4_009.htm
https://pe.usps.com/text/pub52/pub52c4_008.htm#ep344365
My personal take is that in most cases you will probably be fine if you ship an M16 receiver via USPS registered mail from the standpoint that it will get there and back. Hell technically people ship drugs and all sort of contraband via USPS and a lot of it seems to get through.
That said, if you have a problem and USPS loses your package and/or you have an insurance claim I wouldn't want to have an esoteric legal debate with the postmaster as to whether a stripped or upper less M16 lower was legally mailable and/or eligible for insurance compensation. You would be safer (legally speaking as the regs are currently written) shipping it with a stock attached and a rifle length upper. (even if the upper is not attached to the lower but in the same package)
IMHO, the only 100% absolutely clear (not breaking the carriers terms of service) and regulatory/statutory legal way for a non-licensee to ship a stripped or upper less M16 lower receiver is via Fedex Priority Overnight service. The package must also be handed off to a Fedex driver who is scheduled for a pickup or dropped off at the Fedex depot. (i.e. no dropping off at a fedex kinkos)
While I used to use USPS Registered Mail for larger format clearly non concealable machineguns, I now personally ship machineguns (concealable or not) via Fedex Priority overnight AM delivery.
I ship also them early in the week so it will never go over a weekend, I drop them off at the main depot late afternoon to minimize their time hanging out at the depot, and I have them shipped back to the main depot for pickup so to minimize the amount of time spent bouncing around in the last mile truck.
While Fedex insurance is dogshit I still insure them with the hope that if lost it will help spur action on their part to find it. For real insurance I have secondary insurance that covers shipment.
Fedex Priority Overnight is not cheap but on the plus side you also won't be waiting a week or more as your machinegun bounces around the USPS postal system with terrible or inaccurate tracking leaving you to wonder and worry if it will get there or not.
I also don't let the return shipper create the return Fedex label (that way I 100% control the terms, service, and address) and if lost I am the legal shipper and receiver so there is no ambiguity on a claim. I am also very clear with them that the machinegun needs to preferable be dropped off at the main Fedex depot, or I will schedule a driver pickup. Under no terms should my machinegun be return shipped via dropoff at a Fedex Kinkos type location.
Hope this helps.