It sounds like you did as the manual says and kept the original packaging. It's been a while (about 18 months) since I unpacked mine, so I can't recall exactly how the sub fits into its packaging. Would a few visual aids help?

Feet, power cord, and manual go together in a little box with some styrofoam. (Scissors not included.)

Sub goes in the t-shirt with the opening at the bottom (or the top, if the sub's upside down).

Sub does into smaller box with the top up. I don't recall, but I think the box from step one is under the sub at this point.

Small box into big box . I think there was a piece of foam or something that went on top of the inner box, but it had apparently been tossed aside.

Outer box is closed and cat added to hold box shut. (Cat not included.)

Box is delivered to gonk\'s back door. (This step is optional, but highly recommended for optimal performance of sub in gonk's den.)

Oh, and I'll bet that if you need a little help somebody at Outlaw could talk you through it.