Personally I wouldn't mind you went the Ikea-route, having to assemble the case on delivery. I would personally love it, there's nothing like assembling a high-quality product by hand. But Aluminium does make it harder because of the threading, although steel inserts could solve that. But it could drastically lower shipping costs I'd guess, because of serious reduction in packaging in one dimension. And it would also allow easier replacement parts, custom-made parts, upgrade kits, what-not.
Also, optimizing packaging is something that should be done at the macro and micro level, get as many quantities in a shipping container and allowing a good protection of the goods inside each packaged unit.
A really good manual will be needed as well. Nothing worse than trying to put together something with cheap or vague instruction manual.

