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Walmart sells a single gun hard plastic case for $10.00. It has provisions for pad locks and is foam lined. This is practically a throw away price but they work good for this purpose. I'll buy a set of identically keyed pad locks from Harbor Freight and mail a key separately to the recipient. Cardboard cases from UPS or Hertz cost more than these are one time use things and not as secure.
Build a shipping case out of PVC pipe with a solid plug on one end and a screw on cap on the other. If you are worried about security, drill a hole through the screw cap and use a padlock.
If it's a gun you don't care about do the Walmart case, if you sorta care about it use paneling, if you really care about it use 1"x 4" for the frame and 1/4" luan plywood screwed 6" oc (both sides) with sheetrock screws put 1/2" foam insulation sheet top and bottom and place your gun on a 2" piece of foam insulation, trace it and cut out the shape and fit it all together. I then tape all edges so the package handlers do not get splinters. I ship at least 10 guns per year via USPS and have never had a failure.
I send my guns in these boxes with a deposit that I refund when the box is returned; when all come back they are ready to go again. Some people chose to keep the box for storage when that happens I keep the deposit.
If it is a gun you built you can not collect insurance for its value, only the parts you have receipts for and if it is one you bought you can only get whats on the receipt (if you still have it).