A good source of long boxes is your local bike shop. I've posted many odd shaped things over the years & the empty bike carton is perfect, although you need to be prepared to get a saw & some parcel tape to trim it down to size. For cheap couriers, I'd recommend ParcelMonkey & MyHermes. Ypu should be able to send the grille for under £10, but of course you may wish to add a few pounds to cover the addtional materials & time to package it up & print off the labels etc.
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