For a set it's a nuisance, but when I was doing biggish lots of junk - 100-400 cards- I made "wrappers" out of printer paper and wrapped each hundred or so individually. If the cards were nicer I'd use wrecked 80's commons on either end as a bit of protection.
I could fit 400 in the bigger small flat rate box, 2-300 in the smaller one.
I also bought a lot of maybe a couple thousand British cards, lower grade. They came in a flat rate box, with a 91 score set in a binder and a bunch of other 91 score all used as packing material.
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