I agree that they just shouldn't have said it. It was a lighthearted attempt to put a positive spin on a potentially inflammatory announcement, and it backfired by adding even more negative comments and responses from the collectors who despise the choice that was made.
And I have also had experiences where shipping is based on dimensions rather than weight, and I have been charged for, say, thirty pounds when the package really only weighed 12 or 13 but it was large. But the Fett box doesn't seem too big, and I'm not sure whether or not it is an oversized package subject to dimensional shipping charges. With USPS, the length plus girth needs to be more than 84 inches, and I don't think the Fett box is that large.
EDIT: The Fett box is 13x11x22. Total would be 70 inches, well below the 84" mark which would make it a USPS oversized package and raise the charges.