i would def send it in 2 parts and just mark them as machine parts. Ive had a few misc rifle parts i ordered over the net go missing threw the mail. And make sure who ever you go threw to send it make sure you require a singature when it gets there so the jackass’s dont leave it at his front door step for every one too see.
I have shipped a rifle to myself in another state before through UPS, didnt have a problem.
I sent an 11 lb AR-15, 20" bull barrel, intact, via USPS Registered mail for less than $30. With Registered mail, everyone who touches the package has to sign for/off on it. It’s the most secure way to mail a gun and well worth it in my opinion. Plus you don’t have to lie about it, and can take full advantage of insurance if it’s lost or broken in transit.
Probably not any cheaper than UPS at that point, but it’s basically max protection and trackability. I wouldn’t send a gun through the USPS without using registered mail.
i’ve done the same with (parts of) handguns to Bill of triggerwork.net
i’ve also legally sent myself a rifle (out west for coyote hunting), after much research - you can send it to yourself c/o your host or family that you plan on visiting/being with. The key is: from you to you.
I guess, technically, if the OP’s brother would have packed it up and got the label ready and filled it out “shipping it to himself” (back before he left the country), and now that he’s back, the OP would just be taking his previously packed package to the counter for him. but, at this point, shipping to an FFL on the far end is a safe $20-25 to spend.
There’s a lot of bad information in this thread. Before shipping check out the ATF site starting here:
http://www.atf.gov/firearms/faq/unlicensed-persons.html#shipping-firearms-usps