[HumblePie]

I hate to be the bearer of bad news, but I think it's safe to say that the shipping and drayage companies have approved the maximum dimensions in discussion with FIRST. Shipping companies have the right to refuse any shipment based on it not meeting their standards (size, weight, safety). Since you know about the problem now, do you really want to be the one to tell the team that they can't go to Championships because the crate is too large? I'd suggest you break out the power tools one more time. I'd also recommend weighing it to make sure that 150+ pounds of robot and bumpers don't put you over the 400lb maximum and incur extra charges (we learned that one the hard way).