Ok, I know I should have listened to everyone about using (or trying to use) UPS to ship firearm parts but I guess I had a moment.
I talk to Customer Service at Bushmaster about returning my upper because of the indexing issue (rear sight has to be adjusted all the way left for zero). They are totally cool and tell me to ship the upper back via UPS w/insurance.
So I get it packed up and head down to "The UPS Store" to drop it off; so far so good. I fill out the paperwork and hand it and the box w/the upper to the clerk. First he asks me what's in the box; I reply and tell him it's a rifle upper half. He seems to be ok with it until he sees the declared value I put down. He say he'll have to call UPS to verify it's OK. Comes back and tells me that because I want to insure it they can't take it there and that I have to take it to the main depot (45 min away). I said no thanks I'll go to FedEx @ Kinko's. He gets pissed and says as I'm walking out the door "I used to work there; they won't take it either!"
So I decide to take the chance and go over to Kinko's. Guess what? They have no problem shipping it but ask me to open the box so that they can confirm that it is adequately packed (due to the declared cost). Bingo-bango, five minutes later it's on it's way back to Bushmaster.
I knew there was a reason I didn't use UPS......
M590man