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Originally Posted by UlTiMaTeP
I recommend not shipping batteries in the crate it has caused our crate to be overweight twice. Take the batteries to comp via someone driving, it is a lot cheaper than having to pay overweight charges. We made a lighter crate this year, we were over 400 because our crate alone was weighing in close to 250. Also they do make composite skids and crates that can come apart and are very light, it is a good investment. Normal wear and tear and objects that protrude are obviously gonna be hit, scraped or broken. Remember FIRST and FedEx sometimes stack crates, you must design your crate with the ability to withstand 1000 pounds on top of it.
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Unfortunately, some teams cannot drive. For us to go to Nationals it is a 1720 mile drive one way...not big savings of $$$. The thought has crossed my mind to drive there anyway so we can have all of our tools, extra batteries, extra raw materials, etc.