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We almost always have to fill out the White customs forms. The size/weight/value has something to do with the customs form (white or Green) issue, maybe the service level too. We always do Priority Mail.
I'm sure the rules are different for FCM and Parcel.
And considering how many sites refuse to ship APO/FPO, the customers are always very grateful and become repeat customers, as well as 'word of mouth" advertisers for you.
Maybe why the USPS is in such a mess.
You actually don't ship it to the address what happens is you ship to military destination points based by ZIP that then take the package and ship it. All your really paying for is shipping to the point of delivery were the military takes over.
I myself feel it is part of my duty to ship to those guys/gals. Most of the time we don't make any money on the order due to the cost of shipping and the extra goodies we send them adds to the weight of the package. We get quite a few APO's and when they return we get re oders from them along with a nice note thanking us for our support.