I've ordered several times from brownells with great results. However my last two orders I got hammered with huge shipping costs (about 50%) of the cost of the order itself. I phoned and asked why and they said it was the only way they could ship such large items....
I ordered a safety button and forestock for a mossberg 590. Both times could easily fit in a box 1/4 that of a shoe box. But instead they packed it in an enormous box 12" x 24" x 36". Then charged me over $40 for shipping.
This time I ordered the matching stock. I ordered it from there as $90 was cheaper then anywhere local. I specified "cheapest shipping possible" and even sent an email to customer service asking to ensure they packed it properly. Then I got my bill $40 in shipping again, sent priority air mail. I called customer service and they couldn't refund me part of the order nor were they willing to do anything to help. Needless to say this is my last order from brownells.
I know what you are saying and I have always said ship via USPS the cheapest method possible and in the smallest package possible. even if I order a couple small pins or something it comes in a HUGE box. I dont get it. Cant say I recall getting dinged on shipping though. I will tell you to get it shipped USPS whenever possible to avoid the broker fees that UPS or Fedex will charge you.