To prevent cracking during shipping, you will probably want to put stiff cardboard on both sides, and tape it together before putting it in the envelope.
already do so. for the box i had to use for the Mortal combat guys i put 4 pieces of cardboard, packing paper and those big bubbly thingies.
Bulbasuar would probably end up being 8$ as said before, but that is not including shipping and handling.
um, i also think i should inform everyone that trying to make one of these things is immensely harder if its not already pixelated, i can find picture via google very easily but if you would like something thats not i can't guarantee it can be done.
I have a 8-bitcoin right here -
http://i.imgur.com/MZBXj.pngYour good, i have to say. but for my convince at least, i don't think i'd end up doing any orders that can't be found 8-bit style.