There is no single guitar box size, because a dreadnought in a hard case and an electric in a gig bag are different objects. But the decision is quick. Answer what you are shipping, add the clearance that method needs, then check the result against the carrier limits.
What are you actually shipping?
| You are shipping | Measure this | Clearance to add |
|---|---|---|
| Instrument in a hard case | The closed case, latches shut, handle flat | Small and even, enough to load without forcing |
| Instrument in a gig bag | The bag with the instrument inside | Enough at both ends for end blocks, plus depth for the blocks |
| Bare instrument | The guitar, body width at the lower bout, total length | Generous at the headstock end, supported at the neck joint |
| Suspension pack | The instrument plus the suspension film frame | Enough depth that the instrument floats clear of both faces |
Is it going to clear the carrier limit?
Do this before you tool anything. Take your external length, then calculate girth as twice the width plus twice the height. Add the two. US domestic parcel carriers commonly cap a single package at 108 in in length and 165 in in length plus girth, and they apply oversize handling well before those caps. Confirm the current figures with the carrier you use. A box that crosses a threshold can change the cost of every shipment for the life of the product.
Single wall or double wall?
Double wall, in nearly every case. The issue is not the weight, it is the length: a long single wall carton flexes across the middle, which is where the guitar body sits. Full flap construction, where the outer flaps meet across the whole panel, puts a second thickness of board across the top and bottom faces, which is worth having on a box this long.
Do I need a bigger box than the case?
Only enough bigger to load it and to place protection. Extra space is not protection, it is room for the instrument to accelerate before it hits something. If you want more protection, add material, not volume: end blocks, a neck support, corner pads. The method behind all of this, including the three packing approaches and the headstock failure mode, is on our guitar box size guide.
What to send with a quote request
The closed case dimensions or the instrument dimensions, the packed weight, how you intend to block or suspend it, and the quantity. Minimum order is 100 boxes, from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before printing are included, so a carton cut to your case costs no more to tool than a near-standard one. We produce in West Chicago in the US and in Guangzhou in China, and turnaround is quoted per product in three lanes: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days in production plus 2 to 5 days for delivery. For foam cradles, see boxes with foams.
Measure the case closed, run the length plus girth check, and send both numbers. Request a quote and we will size the carton around your packing method.
