I had a box from TRU that looked like it dated Chris Brown, so I figured I'd pop the seals and put it together. After all, I should make enough selling the MISB units I still have to pay for this one, and even if I decide to sell it the used model will still pull what I paid in retail. But I digress...
There was a fair portion of space that could be eliminated internally, but if they do so they should also thicken the outer box, which would counter the smaller box size. It was packaged into 3 smaller, inner boxes (okay, 4 if you count the one the manual was in). With all the bags being numbered, they could have just put it all in the big outer box and saved quite a bit of space. I would say that if it were packed according to content, the outer box could have been up to 20% smaller. That said, there is quite a bit of childish glee popping open a box that size to play with the toys.