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Panels are shipping in 200lb cardboard boxes.  Panels are either vacuum sealed or shrink wrapped, then packed in bubble wrap or other padding.  Some kits with long trim pieces may be packaged into tubes or larger cardboard boxes.  

There is no profit margin in shipping the panels.  The rates posted are based on actual costs.  Domestic orders will be shipped either USPS or FedEx and prices are in line with typical expectations. 

Now, despite being rather affordable to ship items to the US, shipping from the US to international locations is stupidly expensive.  The cheapest rates to ship panels to Europe from the US via the standard carriers like UPS, FedEx, and DHL start around $125.  Price it out.  It’s insane.  16” x 8” x 4”, 2-3lbs.  It will make you cry.

As such, International orders will typically be shipped via USPS First Class Parcel service. This is the cheapest means, but it is a no frills method.  The tracking information is horrible…and often fabricated based on average ship times…having nothing to do with the actual location of your package.  There is no insurance.  If the item is lost, it’s gone.  (To date, that has never happened.  But if it does, don’t worry, I’ll handle it.)  Worst of all, USPS doesn’t handle the final delivery in your country…rather they use contracts with other Parcel services.  The worst of all is in the UK: Parcelforce. They will hold your package ransom for a crazy service fee in excess of £10.  Despite, all of this, your final total ‘landed’ cost is still much less than that of the other private carriers mentioned above.  I wish there was a better way!

In most cases yes.  I often take on custom projects for customers including custom designed panels, cases, synth ‘chops’, and synth restorations.  Sometimes one might have drawn up their own design for a custom project that needs wood panels or a case.  Others might need help to execute a synth rebuild or conversion project.  Either way, use the contact form to let me know what you want to do.  Most of the time I can work it out at a fair price.  Often however, there is a waiting period and tight schedule for getting to these projects.

Most of the time, yes.  But this involves having the original panels, or entire synth on my bench.  My production process starts with measurements of the original panels, then 3d cad modelling.  Next the 3d CAD model is converted to a milling plan using CAM software.  Once the CAM is complete, a prototype will be cut on the CNC machine in an inexpensive wood like pine.  These protoype panels are then fitted to the synth, or compared to the originals, (then burned in the firepit!)  Often, adjustments are required to the 3D cad model, and the process is repeated. Simple designs might require only one pass through this process.   Designs with complicated curves, multi-sided machining, etc. may require multiple iterations to get perfect.

When a simple copy of an existing panel is being made…most of the time I only need the panels.  However, when design changes are required, it is imperative to have the synth on the hand for test fitting.  The design changes included things like making wood sides to replace original panels that were plastic, or replacing wood panels with an improved mounting technique.