You can definitely put an HRAP in a smaller box than what’s used. Heck, the T5 stick basically uses the same basic plastic casing and came in a smaller box to boot, too!
Hori wastes insane amounts of space with the HRAP boxes and I really don’t think they protect those sticks any better than the T5 boxes protected the T5 sticks. It’s B.S. to say that the stock RAP boxes are any better. The sticks are really protected by the thick outer cardboard vanilla packing boxes they were shipped in from whatever Chinese factory they were made at.
The HRAP’s are basically suspended within their 4-color boxes in almost egg carton-like cardboard between thin cardboard walls! That’s protection??? The MadCatz TE’s have better protection in their “collector’s boxes” within their foam end caps!
Main thing you do get charged for in shipping (by any service) is weight. Sure, it can help to reduce the boxsize a bit but those sticks are heavy regardless of what they get shipped in. Shipping internationally is outrageously expensive anyway you slice it once weight slips into the pounds end of scales…