You are better off shipping two boxes for several reasons, as you have discovered.
You are on the right track with the packing: double box with the destination, telephone numbers, and return address written on both boxes and on several sides. Double wall corrugate is ideal for your outer box (U-Line is a great source for boxes), and you can buy bubble wrap at Wal-Mart inexpensively. Empty water bottles also make excellent space fillers. Use the best 3M tape as there are several grades. I bought a carton stapler but that's probably a little OCD.
Now I gotta decide what to do with the 036. Maybe I should do my own porting experiment since I got it so cheap.