Oh yes, the frankenears are very annoying because they like to break!
As for XT, I notice that one of my XTs was loose. The foam had deteriorated. I think the problem lies in the dirty-disgusting-whatever grease that was used on some XTs. When this greasy thing rots, it rots the foam with it or makes the foam shrink - whatever the case, one of my XTs was actually 'loose' and the hammers moved very easily. They could be disarranged simply by me pulling up a keycap!
On WCASS's advice I made the casing tight with a piece of heavy paper between the PCB and the metal plate. Unfortunately, this damn XT refused to function after that. I still don't know why and it is still one of my pending projects.
And oh yes, those people located CONUS have NO IDEA how exorbitant volumetric pricing is. It's nice to live in the center of the civilized world aka USA. The peasants living on the fringes of the Middle Democracy don't have it so good with free Amazon shipping and huge mail in rebates and what have you.
I think that the XT and AT are pretty robust in handling (except for those stupid "Frankenstein" ears that operate the legs) because they are relatively small, tight, and and they do not flex much. I have never had any problem with the XT and physical damage, beyond the "skin" abrasion issue, and only once have I received an AT with any cracks. Opening the case is another matter.
The big ones, on the other hand, are far more prone to damage, for the reasons I described earlier.
For good shipping, they need to be protected from side-to-side shocks. Good padding at the corners is essential, and they should not flop around.
Of course, double-boxing with loose styrofoam in each is best, but that can drive shipping costs very high because carriers use voodoo-like calculations incorporating both size and weight, and if you can't use flat rate packaging, you pay a huge premium.
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