Packing a saw for shipment is kind of a clumsy affair, usually involving customizing a box and then figuring out how best to keep the horns from getting chipped or the plate bent. Described below is my particular method how to do this, and I hope it helps.
The first thing you'll want to do is to wrap up your saw in bubble wrap, newspaper, kraft paper, anything that will suffice to cover the wood and metal. The pic to the right shows how I typically wrap up my Bad Axe saws with indented kraft paper prior to boxing them.
This is the most important step. Use some foam rubber, styrofoam, bubble wrap or some other kind of cushioning material to wrap around the handle and the toe end of the saw to suspend it inside the box, such that no one part of the saw will come into contact with the box. Have enough void-fill material to fill the gaps.
Add void fill: packing peanuts, wadded-up newspaper, quilted kraft paper, bubble wrap, anything that will cushion the saw on the top, bottom and sides. Particularly important is to pad the handle and toe ends with foam or something a little more dense. This will stabilize the saw in the box and protect the delicate edges when the box is dropped, kicked, or bounced at some point in transit.
After filling the void, use a quality tape to seal the box and you're done.
In summary, boxes in transit get bent, shoved, dropped and plopped. The key thing to remember when packing your saw is to suspend it in a box with reinforced padding around the handle and toe end of the sawplate, with plenty of void-fill and some blocking on top, bottom and sides.
About the Packing Materials I Use:
For those of you working in industries where finding a good source for environmentally-friendly packaging materials has become an imperative, you might find the following products I use and their suppliers useful. I use 100% recycled products for my packaging, which includes the corrugated box, the non-GMO corn-based bracing foam, the indented kraft paper with which I wrap the saw, and the wet-activated tape I seal everything up with. A blog posting that describes the companies who supply these materials, Salazar Packaging and Adams Foam, can be found here. These are great companies with responsible products friendly to the environment.