I don't want to presume what the difference is between the component cost and your selling price, but you could add on your own insurance.

For example add $$$ to each order to pay for the odd one that goes missing, I have never had anything go missing, so going with the other figures quoted we could assume that 75% would arrive OK. So for 10 orders that would leave $175 component cost to recover (for example only) so add $17 to each order insurance send them via the cheap mothod and the shipping cost is almost halved.

I would say that it is more likley that 95%+ of orders would arrive OK in time. my dock took 5 weeks but only cost $15 and weighs as much as 100's of boards.

I am in no way complaining etc... (don't want to upset anyone) I can understand that FedEx is way easier for you, it is just for me it is a real pain and will cost me almost the cost of the board again in shipping and customs.

Cheers

Cris.