People constantly ask about shipping guns and ammo. Here is some information that may help in the future:

SHIPPING GUNS

Non-FFL
Intrastate (within a state) Long Arms (Rifles, Shotguns): A non FFL can ship a long arm to an eligible person or a FFL within the state via common carrier (UPS, FedEx, etc.) or USPS.

Intrastate Handguns: A non-FFL can ONLY ship a handgun to an eligible person within the state through the eligible persons FFL. The handgun can ONLY be shipped to the receiving FFL via common carrier (UPS, FedEx, etc.). If the receiving FFL WILL NOT accept a gun from a non-FFL, then the shipper will need to have a FFL ship it for them. A non-FFL CANNOT use USPS to ship a handgun.

NOTE: the above is specific to PA, other states may have different laws (except that a non FFL cannot use the USPS to ship handguns no matter what state they live in).

Interstate (between different states) Long Arms: A non-FFL can ONLY ship a long arm to an eligible person through an FFL in any state via common carrier (UPS, FedEx, etc.) or USPS. A non-FFL CANNOT ship a long arm directly to another non-FFL in a different state. If the receiving FFL WILL NOT accept a gun from a non-FFL, then the shipper will need to have a FFL ship it for them.

Interstate Handguns: A non-FFL can ONLY ship a handgun to an eligible person through an FFL in any state via common carrier (UPS, FedEx, etc.). A non-FFL CANNOT ship a handgun directly to another non-FFL in a different state. If the receiving FFL WILL NOT accept a handgun from a non-FFL, then the shipper will need to have a FFL ship it for them. A non-FFL CANNOT use USPS to ship a handgun.

SHIPPING GUNS FOR REPAIRS/CUSTOMIZATION, ETC.
Intrastate/Interstate: Long Arms; USPS, FedEx, UPS or any commercial carrier. Handguns; FedEx, UPS or any commercial carrier (unless using a FFL to ship, then USPS can be used).
After the repair/customization, etc., the FFL can return the gun directly to the owner as no change of ownership occurred. Be aware that some gunsmiths may want everything done through a FFL (shipping and return). That is their prerogative.

ABOUT SHIPPING WITH USPS: As long as it is a long arm USPS will send it. You do NOT need to fill out a USPS Form 1508. This form can only be used by manufacturers or dealers of firearms. If a USPS employee tells you that you can't (ship a long arm) they are wrong. They need to read their own regulations. If they argue, ask for the Postmaster. If the Postmaster tells you that you can't, go on line and print out the appropriate section and show them. If they still won't then write to the Postmaster General. (USPS Domestic Mail Manual - Section 601: Mailability:
From page 59:
11.3: Rifles and Shotguns
Although unloaded rifles and shotguns not precluded by 11.1.1e and 11.1.2 are mailable, mailers must comply with the Gun Control Act of 1968, Public Law 90-618, 18 USC 921, et seq., and the rules and regulations promulgated thereunder, 27 CFR 178, as well as state and local laws. The mailer may be required by the USPS to establish, by opening the parcel or by written certification, that the gun is unloaded and not precluded by 11.1.1e.

FROM THE BATFE:
May a nonlicensee ship a firearm by common or contract carrier?

A nonlicensee may ship a firearm by a common or contract carrier to a resident of his or her own State or to a licensee in any State. A common or contract carrier must be used to ship a handgun. In addition, Federal law requires that the carrier be notified that the shipment contains a firearm and prohibits common or contract carriers from requiring or causing any label to be placed on any package indicating that it contains a firearm.
[18 U.S.C. 922(a)(2)(A), 922(a) (3), 922(a)(5) and 922(e), 27 CFR 478.31 and 478.30]

May a nonlicensee ship a firearm through the U.S. Postal Service?

A nonlicensee may not transfer a firearm to a non-licensed resident of another State. A nonlicensee may mail a shotgun or rifle to a resident of his or her own State or to a licensee in any State. The Postal Service recommends that long guns be sent by registered mail and that no marking of any kind which would indicate the nature of the contents be placed on the outside of any parcel containing firearms. Handguns are not mailable. A common or contract carrier must be used to ship a handgun.
[18 U.S.C. 1715, 922(a)(3), 922(a)(5) and 922 (a)(2)(A)]


SHIPPING LOADED AMMUNITION in the United States:

The first rule is that loaded ammunition can’t be shipped through the US MAIL. The United States Postal Service will not allow shipment of loaded ammunition. Inert ammunition and components may be sent through the mail, but should be clearly marked as inert on a small note included inside the package to prevent a misunderstanding.

USPS Regs about explosives (which ammunition is considered by USPS definition)

Domestic Mail Air Transportation: Prohibited
Domestic Mail Surface Transportation: Prohibited except with written permission as allowed in 10.11.2.
10.11.2 Mailability: Explosives are prohibited in international mail. Explosives are prohibited in the domestic mail via air transportation. For domestic surface transportation, explosives are prohibited except for certain Division 1.4S toy propellant devices and safety fuses specifically approved by the manager of Mailing Standards

International Mail: Prohibited

Both the United Parcel Service (UPS) and Federal Express (FedEx) will provide ground shipment of loaded small arms ammunition up through .50 caliber. For packages up to 20 pounds, the ammunition must be packed in boxes with at least a 200 pound bursting strength and be marked on the outside:

ORM-D
Small Arms Ammunition

Material marked ORM-D and shipped by surface transportation do not require hazardous shipping papers, simply an ORM-D Consumer Commodity marking on the box. This marking can either be in the form of a ORM-D sticker, or written by hand. If written by hand the letters "ORM-D" must be enclosed by a rectangle

Both UPS and FedEx Ground do not require a hazardous shipping contract to ship ORM-D packages.

This information may be dated and you should check with the companies’ hazardous materials information hotlines.

The transportation of small arms ammunition is regulated by the Federal government in 49CFR173.63. This regulation also defines packaging requirements. To determine the specific hazardous material code for ammunition (UN code) other than that which 49CFR173.63 authorized to be shipped as ORM-D, contact the Department of Transportation Hazardous Materials Hotline (800) 467-4922.

The ATF also regulates the interstate transportation of small arms ammunition. A Federal Firearms License (FFL) is not required to either ship or receive small arms ammunition shipped interstate in the US. Basically the ATF, in 27CFR178, prohibits the shipment of armor piercing ammunition and prohibits the shipment of any ammunition to a person known to:
• Be under 21 years of age
• Live in a state where the shipment is prohibited
• Be under indictment for, or, has been convicted in any court of a crime punishable by imprisonment for a term exceeding 1 year
• Be a fugitive from justice
• Be an unlawful user of or addicted to any controlled substance
• Have been adjudicated as a mental defective or has been committed to any mental institution
• Be an alien illegally or unlawfully in the United States

If you do not know the person you are shipping the ammunition to, you may want to have the person sign a statement certifying that they meet the requirements listed above.

DO NOT RELY ON THIS ARTICLE AS YOUR AUTHORITY TO SHIP SMALL ARMS, OR AMMUNITION. CHECK WITH ALL PARTIES CONCERNED PRIOR TO SHIPMENT.

(Thanks to Xringshooter for this write-up)