Yes, I agree. The CMs we encountered were VERY fussy (although very nice about it) about how the box was. The box needs to be able to close -- without any gapping. My DH, who is the king of packing the trunk, spent forever getting everything in there. It was some weird kind of challenge for him -- I was trying to decide what we were going to have to leave out. But, oh no!, he wasn't going to leave anything out!
One suggestion I would give to people who are looking at getting some -- make sure you look at what comes with the typical Mr. Potato Head. I put some shoes in our box because I thought they were supposed to be "Minnie" shoes, but they turned out to be ones that came with our original potato. Also, definitely buy the potato somewhere else. We buy strictly the items you can't get elsewhere.
The box dimensions are: 7 inches tall, 5 inches wide, and 4 inches deep on the top or 7 inches tall, 4 inches wide and 5 inches deep on the top, depending on how you look at it. Now, I'm not sure if this box is from our DW trip in 2002 or from DL trip 2004. They may have different box sizes. Does anyone know if they change the size?
We're going to WDW in May 06 -- for the first time with 2 children. I'm afraid we'll have to buy double the parts this time!