I did some research on the interwebs about whether this would work or not, but there is nothing definitive.
A standard long box holds about 250 issues with bags and boards. I didn't put it on a scale, but I believe it's in the 40-50 lb range.
A couple of years ago, I came across 2 reinforced boxes approximately the same size as a long box. I don't remember what the original purpose was for them, but they worked out great. They held about 225 issues each and were pre-padded with styrofoam so I didn't have to add anything else, just tape them shut.
I'll probably just go with the smaller boxes, insure them, and hope they all make it.
Thanks for the feedback