Hi, in an effort to share infomation about shipping costs, I've compiled some info that includes some links to the information at the Post Office and also the cost of sending my first four packages to South Africa.
I found the shipping information at the USPS (United States Postal Service) -
http://www.usps.com/
International Mail Categories
The two that seem to apply for our purposes are (1) Priority Mail International - Flat-rate boxes and (2) First-Class Mail International - Large Envelopes (Flats) and Packages
This link goes to the info about the Priority Mail Flat Rate box rates -International Mail:
flat box rates
For the medium size box (provided by the Post Office) $41.95
For the large sixe box (provided by the Post Office) $53.95
The prices reflect the recent rate hike. You can stuff the box FULL, but the maximum weight limit is 20 pounds. Both boxes are similar in size to the boxes that I normally use to send things via the First Class International rate.
Remember to package your squares in ZipLock or other plastic bags and squeeze as much air out as you can, also mark the outside of the boxes with NO COMMERCIAL VALUE and FOR CHARITY. The customs form should say $0 value (although my Post Office insists on entering a $1 value).
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I've been keeping track of the things I've sent since I joined the K-A-S group on Ravelry.
All of these items were shipped via First Class International rate, from the US in boxes that I provided.
Box #, total weight, items shipped, total cost
#1 - 1 lb. +1 oz. (9 wool squares + some yarn) - cost $11.98
#2 - just under 2 lbs. (16 squares + 11 hats) - cost $16.99
#3 - 1 lb., 1.2 oz. (6 squares & 6 hats) - cost $11.98
#4 - 2 lbs. 6.7 oz.(12 squares + 6 youth-adult sized hats) - cost $20.33
I hope more people will add to this thread!