Quoted: Check the Fed Ex rules, it clearly states it must be overnight (the girl in the store pointed it out to me once and its posted on a couple other boards)
USPS will ship pistols from a Non FFL to a FFL if you have their lic... You musta just dealt with one of their many workers who are clueless. You can't ship through "outlets" like UPS Store, Fed Ex etc... You can't schedule a pick up at your home or office for a firearm either... Only an FFL has that luxury.
Always bring a copy of the license of the FFL you are shipping to and tell them exactly what you are shipping (a unloaded firearm in a secured locked case)
Also, make sure to slide a copy of the FFL license in the case with the firearm as well... That way if it is "lost" they have no excuse for not getting it to the dealer.
Make sure you always insure it...
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YMMV, my experience was on several different occasions and different people. Always FedEx Express Saver (1-2 days depending on the service in the area shipped to) and not overnight, it was always insured over full value, and the package included the FFL.
I don't get involved with the b.s. they make up to avoid the liability of the workers hands. They visually saw the pistol before I sealed it w/the FFL in the box. Each and every time they shipped it the same way. Remember this is policy not laws (except for the USPS) so their interpretation can, and will vary depending on the person at the counter, and training in stated policy.
All that said, be prepared for what may or may not be required, cover you own, and let them deal with the "policy".