advice on sending a bike in a box

Don't want to send it in a bike box with loads of air!!!

If you've got a local shop that sells high-end stuff they probably chuck away loads of frame-size boxes. Failing that, bike box, Stanley knife, parcel tape, trim to fit :)
 
Why does air make a difference?

As long as the box falls within the guidelines of the courier...

I had to cut a box down from 53" to 48".. but then I couldn't leave a wheel attached.. bit of a squeeze getting a dismantled bike in a box :?

Early indications are that it arrived safe and well.... was proper stressing about it getting knack'd en-route...

And now I have another to send... don't now whether I'll be sending whole bikes again... it's not a positive adventure for me.
 
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