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@curraone wrote:

The Australia Post small domestic letter with tracking (about DL size) has a maximum thickness of 5mm - so I don't see how you can get a padded bag and the item in it.

 

And this is probably why the PO staff are putting their foot down?

 

The large Australia Post domestic letter with tracking (about A4 size) has a maximum thickness of 20mm, but of course it costs about $5.50

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there are 3 sizes you are aware of that??   the small is 5mm limited (DL)  med and large are 2 cm limited the (C4 and C5)