First off, I certainly wouldn't try this with that Glen Blue that is on Ebay right now...and I won't guarantee that it would work for everyone, BUT, I successfully boxed up and shipped my beat up brownie, and brought it home Sunday night on a direct Southwest flight from St. Louis to Las Vegas.
I bought an extra large box from Home Depot. ($1.97)
Slipped the bowl of the H code brownie in the box.
Put the lid in upside down into the bowl.
Placed the legs, wheels, and triangle in the lid and then placed the triangle on top. (Later I taped the legs together, the pic is before I decided to do this step.)
I stuffed newspaper around the sides as best I could, and put another cardboard sheet on top of it all.
Then I slit the edges of the box so it would lay flat on top, and taped it extensively with packing tape.
My final dimensions were 22.5 inches high, 22.5 inches wide, 14 inches high=59 inches total. Southwest allows you up to 62 inches total length + width + height so I had three inches to spare.
Sunday night at Lambert was not too busy, the lady at the Southwest counter asked me what I had in the box, and I proudly said, "A Weber grill." She asked no further questions, had me sign a release saying I wouldn't hold Southwest responsible for damages, and away we went.
After 3.5 hours in the air, I was curious to see what would come out of the baggage carousel, and the box, though a little worse for wear, looked OK. Got home at midnight, but I did a quick unboxing to find all OK.
Last night I bought a new ash sweep for $5 and installed it, and tonight I put it all together. Brownies are so interesting to me because they look so different depending on the light. I know this one is far from perfect, but it will get a lot of love and care for years to come...she's a cooker, not a looker for sure. Finally, I really love the handles my dad made for me. He had a VERY serious health scare this summer, and I am extremely happy that he's back to his woodworking ways.