I think it was Andrew who had a great way to send seeds. Instead of the expense of those too large bubble envelopes, He used bubble wrap directly around the seed packets and taped it around them. Than he put them in a card size envelope with a note card around them. They came to me with no problems.
I just sent 2 envelopes out for some forum member in that manner and it only cost $.42. I reused old bubble wrap I cut out of an old envelope. I'll let you know when they receive them.