Yeah, the gist of it is that the USPS provides priority boxes for free as long as you use them for priority mail. The only time I ever had an issue was probably 17 years ago, I tried to mail books via media mail in a covered up box. Now, before I get crucified, it was a reused box, in other words, it had been mailed to me priority. I didn't have another box at the time and was trying to find something to fit these books, so it was what I had. My "argument" to my postmaster was that I was reusing it otherwise it was being tossed, in other words, it was a throwaway or I was recycling it. It didn't fly. I at the time didn't realize the rules. But now, they actually check it quite often. What really raised the random checks is with the ability to print postage at home, according to my local PO who I have a first name basis relationship with! (I mail too much), they now perform these checks b/c they have too many packages dropped off with printed postage that is incorrect, either the wrong box, but the main culprit is weight, dimensions and zip code. Apparently, a lot of home mailers do not understand that sending a larger than 12x12 package from Maryland to California has to have correct size and weight b/c the charge is "dimensional", not just weight. For example a 9 lb box from Maryland to NJ is say $15, but the same box with sizing over 12 inches cubed to Los Angeles is $65. You can see how it can be a big problem.
The whole mess apparently causes a lot of lost revenue, so they are trying to monitor it.
TD