I once sent two ~2kg boxes measuring about 11"x11"x3" on a 30kg hard wood pallet. But it was food going to a grocery distribution centre. Between only receiving trucks and secure supply chains, it's the only way to get it done.Of course we never went this far...
http://www.theregister.co.uk/2008/07/23/enormouse/
Obviously a money loosing proposition for our company, but those are the sort of things you do for your customers...
I use 1/16" for steel for just about everything. Obviously larger rod for larger stuff & building up & filling, but 1/16 is my go-to rod.




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