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I didn't really like the idea of using those carboard envelopes; seems way to fragile to ship a shirt in, especially more than one. I'm using the tyvex envelopes right now myself which are sturdier but not flat rate so they cost a bit more when shipping more than 1 shirt.

Btw, jdr: The shirts I'm shipping weigh over half a pound each, so even 2 shirts passes the limit. Perhaps with the lower grade lightweight shirts or smaller sizes you can do 2 though.
 
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