I got a regular bike box from the LBS for free. 54x31x8. I cut it down to 51x31x8 to have a proper fit to the bike. Came with some packing materials, I used some, pitched the rest. I bought 8 pipe insulators, zip ties and a 3 Musketeers bar from Home Depot for $27. I used 7 pipe insulators, half of the zip ties and ate the candy bar while packing. Took me 90 minutes. Figure someone who knows what to do can do it in under 60 minutes. But I charge nothing for labor. My LBS shop rate is $120/hour, billed in 15-minute increments. I can't image them charging less than $105 to pack a bike. No more than $150.
As I wrote in another thread. Chicago to Buffalo is $56 for shipping. Chicago to Toronto is $103. $500 insurance.
the 3 musketeers bar was the critical purchase
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Life is too short not to ride the best bike you have, as much as you can
(looking for Torpado Super light frame/fork or for Raleigh International frame fork 58cm)