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Not sure about the size but you can buy individual boxes at http://www.meyerhatchery.com/productlist.a5w?session.subcategory=Shipping Boxes&subcat=1079&session.subcat_id=1079&cat=1027 the link doesn't always work well but if not click on poultry supplies and then shipping boxes. Chop up...

You can ship at any age but after day-old, overnight mail is essential and avoid very hot weather.