legal ways to send the Encore frame back to the factorry?

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USPS should work fine. Get a copy of the rules or laws yourself as the person behind the counter may tell you different than what is so, happened to me. Regulations should be available online.
 
B8) May a nonlicensee ship a firearm through the U. S. Postal Service? [Back]
A nonlicensee may mail a shotgun or rifle to a resident of his or her own state or to a licensee in any state. Handguns are not mailable. A common or contract carrier must be used to ship a handgun. A nonlicensee may not transfer any firearm to a nonlicensed resident of another state. The Postal Service recommends that longguns 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
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Or a better explanation

Notes on specific shippers:

US Mail: An unlicensed person can ship a rifle or shotgun by US Mail. Unlicensed persons cannot ship a handgun by US Mail. Postal regulations allow the Post Office to open your package for inspection. Ammunition cannot be shipped by US Mail. You can search the US Post Offer Postal Explorer site for specific USPS regulations regarding firearms and ammunition.

FedEx: FedEx will only ship firearms via their Priority Overnight service. Ammunition must be shipped as dangerous goods.

UPS: UPS will accept handgun shipments by Next Day Air only. Rifles and shotguns can be shipped by UPS ground service. UPS will accept shipments of ammunition. UPS does not allow shipment of firearms FROM an unlicensed person (even to an FFL), unless the stated reason for the firearm shipment is for repair or modifications.

Most other shippers will no longer accept firearm shipments. Airborne and Roadway have specifically prohibited firearm shipments.
 
USPS goes by the same definitions as BATFE since they are in Federal law. No mailing of a handgun or handgun frame/receiver by anyone but an FFL dealer.

Did you call the company? On warranty returns, most companies will send you a UPS/FedEx label so shipping costs you nothing. Or, if you bought the gun from a dealer, he may be willing to ship it back by mail which will cost less.

Jim
 
The USPS does NOT go by BATF rules, regulations, and definitions. They are stricter. I got in a position where I had to mail a pellet pistol; the only North American Walther service center is in Canada and a common carrier like UPS could not get it though Canadian Customs. The post office would not take it from me; THEIR definition of a handgun includes air guns. I had to get a FFL to handle it. (Actually he just signed the form and let me do the leg work with the hysterical postal clerk and the postmaster.)
 
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