LugLess shipping guide: sizes, weights, and how we charge
Learn how billable weight works, how to measure your bag, and how to pick the right category before you book.
LugLess shipping is priced by billable weight, which is the higher of your bag's actual weight or its dimensional (size-based) weight. That means a large, light bag can cost more than a small, heavy one, because carriers charge for the space your shipment takes up. Always confirm your size category and rate using the LugLess shipping calculator before you book.
How LugLess calculates shipping
Every shipment has two weights. The first is what shows up on the scale. The second is dimensional weight, which is what your bag would weigh if it were filled solid based on its size. We charge based on whichever is greater. That is billable weight.
Here is the calculation carriers use:
Actual weight
What your packed bag weighs on a scale.
Dimensional weight
Based on the space your shipment occupies.
L x W x H ÷ 139Billable weight = the higher of the two.
Carriers like FedEx and UPS use lasers to scan and measure every package as it moves through the network, so the dimensions you provided at booking will be verified. If they are off, your final bill gets adjusted.
82% of LugLess shipments are billed on dimensional weight, not actual weight. Even if your bag feels light, its size is probably what is setting the rate.
How to measure your luggage or box for shipping
Measure length, width, and height
Measure each dimension at the longest, widest, and tallest points, including any wheels, handles, or external pockets. Round each measurement up to the nearest whole inch. Carriers always round up, so you should too.
Weigh your item
Use a luggage scale or step on a bathroom scale holding your packed bag, then subtract your own weight. Make sure everything you are shipping is inside before you weigh.
Calculate dimensional weight
Multiply length by width by height, then divide by 139. The result is the dimensional weight in pounds. Compare it to your actual weight. The higher number is your billable weight.
Use the LugLess calculator to confirm
Math is hard, calculators are easy. Plug your numbers into the shipping calculator to confirm your final size category and cost before you book. Always confirm here. The calculator does the heavy lifting.
LugLess size and weight limits
LugLess works within the limits of our carrier partners, which means there are some hard ceilings on what we can ship.
Maximum size
- Length plus girth must not exceed 165 inches (419 cm)
- Girth is calculated as (2 x width) + (2 x height)
- Packages over this limit cannot ship. If somehow accepted by a carrier, fees can reach $2,000 per package
Maximum weight
- Standard LugLess labels cover up to 75 billable pounds per item
- Recommended: under 90 lbs billable weight per item
- Hard ceiling: 100 lbs. Shipments over 100 lbs may incur handling charges of up to $1,500 per package and are not guaranteed to ship
Items between 75 and 90 lbs ship as Oversize and are billed for the overage at a low pro-rated per-pound rate. Anything over 90 lbs is automatically classified as a Large Package. If your bag is right at the edge of these limits, the calculator will flag it. Better to know before drop-off than to find out from a fee notification.
What counts as a Large Package for air shipping
Large Package is a specific carrier classification that triggers extra fees. Your shipment is considered a Large Package if it meets any one of these:
- Billable weight of 90 lbs or more
- Length plus girth exceeds 130 inches (330 cm)
- Length alone exceeds 96 inches (244 cm)
Large Packages are subject to a $170 surcharge and a minimum billable weight of 90 lbs, even if the actual weight is lower. They can also trigger "additional handling," which voids all LugLess guarantees. The easiest way to avoid all of this is to ship in a corrugated cardboard box and remove or restrain any straps and handles that could make your bag scan larger than it really is.
LugLess size categories (simplified)
LugLess offers nine shipping categories based on billable weight. Here are the most common ones to help you find your match:
| Category | Typical Use | Billable Weight |
|---|---|---|
| Carry On | Small suitcase or duffel | 25 lbs |
| Checked | Standard suitcase | 50 lbs |
| Oversize | Large suitcase or duffel | 75 lbs |
| Golf Clubs | Standard golf travel bag | 50 lbs |
| Skis | Ski bag with boots | 45 lbs |
| Snowboard | Snowboard bag with boots | 50 lbs |
| Boxes (Little / Big / Oversize) | Corrugated boxes for non-fragile items | 25 / 50 / 75 lbs |
If your shipment does not fit one of these categories cleanly, pick the closest one. Carriers will measure and weigh your item during transit, and if there is an overage, you will be charged a low pro-rated per-pound rate. No surprise bills, just an adjustment on the back end.
Why size matters as much as weight when shipping by air
Most people assume shipping is priced by weight alone. It is not. Carriers charge for the space your shipment takes up in their trucks and planes, because that space is finite. A pillow weighs almost nothing, but if you ship one in a giant box, you are paying for the truck capacity it occupies, not the pound it weighs.
That is why dimensional weight exists. A bulky bag with light contents can easily cost more than a smaller bag packed dense. When in doubt, pack smaller before shipping bigger.
How to avoid extra charges from carriers
A little prep before booking saves you from rate adjustments later. Run through this list before you ship:
Measure accurately at the longest, widest, and tallest points and round up
Do not underestimate dimensions to save a few dollars at booking. Carriers will catch it
Stay under 90 lbs billable weight to avoid Large Package surcharges
Pick the correct size category based on real measurements, not what you wish they were
Ship in a corrugated cardboard box when possible to avoid dimensional surprises
Restrain or remove straps and external handles that can throw off carrier scans
Use the shipping calculator to verify your measurements and category before you book. Two minutes now, no awkward emails later.
Frequently asked questions about LugLess size and weight
What is the billable weight for luggage shipping?
Billable weight is the higher of your bag's actual scale weight or its dimensional weight. Dimensional weight is calculated by multiplying length by width by height and dividing by 139. Carriers charge based on whichever number is greater, since pricing reflects both weight and the space your shipment occupies.
How do I measure my suitcase for shipping?
Measure length, width, and height at the longest, widest, and tallest points, including any wheels, handles, and external pockets. Round each measurement up to the next whole inch. Then weigh your packed bag on a luggage scale or bathroom scale.
What happens if my bag is heavier than expected?
Carriers weigh and measure every package multiple times during transit. If your bag exceeds the billable weight you booked, you will be charged a low pro-rated per-pound rate for the overage. There is no penalty if your bag is lighter, but carriers do not refund underweight shipments either.
Is there a maximum size for luggage shipping?
Yes. Length plus girth combined must not exceed 165 inches. Packages over this limit cannot ship through our carrier network, and if somehow accepted, can incur fees of up to $2,000 per package. Most luggage and sports gear stay well within this limit.
Why is my shipping cost based on size?
Carriers charge for both weight and space. A large, light item still occupies space on a truck or plane that could hold other shipments, so dimensional weight reflects the cost of that capacity. About 82% of LugLess shipments are billed based on dimensional weight rather than scale weight.
Can I ship oversized luggage?
Yes, but it may fall into the Large Package category, which triggers a $170 surcharge and a minimum billable weight of 90 lbs. Large Packages are also subject to additional handling, which voids all LugLess guarantees. The shipping calculator will tell you exactly what category your item falls into before you book.
Know your size. Skip the surprises.
The LugLess calculator measures, weighs, and prices your shipment in seconds.