I place the note in a mylar holder, then carefully tape very small squares to hold it to some card, then use some scrap clean paper to fold around it, then place it into a hard photo mailer. It's very secure. On the outside, I'll also write "Photo's inside, please do not Bend". If its a high priced item, I will sometimes use a DVD mailer box instead.
I put them between two pieces of cardboard and tape up the edges. I write on the piece of card for people to be careful opening it because the notes are close to the edge.
When using cardboard as protection it should be flat and not corrugated. I have received a note packed using corrugated cardboard that left impressions on the note after it had come under pressure in the postal process.
I cut a Kanga note sheet (3 per page, carboard one side, clear plastic on the other) into three. I put the note in there, tape the three open edges. Cut two pieces of flat (not corrugated, as Pedro mentioned) to size, tape those together around the cut Kanga sheet. Post in registered.
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