Yes, did that a few times as well: not for an OS (but an antivirus product, so close-ish...) and not with Egghead but mostly with CompUSA and Fry's (both now also long gone, I think?). This was at a time when it was theoretically already possible to try/buy software over the Internet, but the resulting clogging of our connection lead to too many complaints, so a road trip it was!

Other than the bugs/extreme performance regressions they turned up in our product, the most interesting takeaways from these exercises were that: 1. most consumer software is really, really bad; 2. good package design is really, really hard.

It may be hard to imagine now, but unboxing software used to be quite exciting. How many manuals? How good? Early software releases had pretty good documentation: I still fondly remember the first editions of Microsoft's developer tools as well as their Office suite, which came with a full set of printed decent-quality manuals. That practice went out of the window for good shortly after, though, and online documentation has IMHO never reached the same quality. But that may just be the nostalgia speaking...