Jim, yes, you are right. The cohesive corrugated cardboard wrap is very good for someone who is very active in mailing a few chips all the time. It is fast, time-saving, and adds a little extra protection. In my other post above about this I did mention that it costs just 6 cents each if you buy it in bulk the way you do ( see http://www.thechipboard.com/cgi-bin/bbs521/webbbs_config.pl/noframes/read/634203#m_634203 ). Sorry I didn't mention it in this thread.

Incidentally, up to now, I have been sandwiching the chips between fairly heavy cardboad, and paying the parcel rate. I will start using my wrapped paper approach from now on and see how it works at letter rate. The key to the latter approach is taping the stuff well.

Does the cohesive corrugated cardboard wrap add any extra thickness to the end product? It seems to me that if it did, the letter would be over 1/4". And if it didn't add extra thickness, it wouldn't afford any more protection than my simple wrapped paper approach?

The other advantage of my approach is the saving of about 30 cents per shipment as opposed to the retail cost of buying from an outfit like J.P.s Corner ( http://jpscorner.com/Bubble_Safety_Mailers.htm#Safety ).

Robert