UPDATE. The link for the image is now available here: http://www.mediafire.com/?9cus1a0b3hcg48x
This tutorial shows how to make one for a few bucks if anything at all, as the materials are pretty common.
The initial idea was found on StevesForums.
Step 1: Gather the Tools & Materials.
1. DVD Case (AOL does come in handy).
2. Thin (flexible) plastic binder. Both plastics may be substituted with heavy (but thin) cardboard/matte-board.
3. Adhesive spray or fixative. Artists adhesive works, but I found that carpet adhesive works much better as it is more flexible.
4. Small piece of aluminum foil.
5. The CD Disk Tray template (right-click, "Save Link As").
The tools are as follows:
1. Razer blade.
3. Band-aids are optional but come in handy when the razor gets your finger. Trust me.
Step 2: Prepare the Top Layer.
Print the Disk Tray Template out on plain paper but be sure you print at the actual size! I put the measurement in cm on the tray so you can tell if it is true-to-size once printed.
Spray a bit of fixative on the plastic and adhere the paper to it. Be sure the paper fits the plastic and doesn't overhang on either side. It is okay to overhang at the bottom (see picture).
Next spray some fixative to the paper and stick an old CD/DVD to it. You may use the template (cut INSIDE the line, not ON) but I find that tracing a disk is easier than tracing a line.
Step 3: Cut the Top Layer.
Now, if needed, pull off the paper and continue SLOWLY cutting your original marks. If the paper is not in the way or is stuck you may leave it. All you are doing is making deeper and deeper cuts until it finally cuts through. Going too fast will either make you mess us and cut outside the line or will cause you to cut through the plastic and right into your finger. I have a few cuts to prove it.
Once the pieces are completely removed you can smooth out the cuts with the razer (pictured). Try to make the circle just big enough to fit the disk but not too big that the disk moves around.
Step 4: Cut the Botom Layer.
Remove the paper from the clear plastic.
Now lay the top (black) layer on top of this new plastic piece to see how closely they match. They should be near identical in width. Mark the squares on the clear sheet as we will need to know where to adhere the foil.
Spray a bit of adhesive on the clear plastic and adhere two pieces of foil (shiny side up!)- enough that the holes in the black piece are filled with foil. (see picture). The foil is needed because the printer looks for the reflection of light and will reject the tray if it is not present.
Now spray the BACK side of the black plastic so that it can adhere to the clear plastic. Spray the black instead of clear because we do not want to dull the shiny foil on the clear piece. Spray enough to completely coat the back of the black plastic. Now stick it to the clear plastic and move it around to ensure complete contact.
The last pictures show the front and back.
Now try it in the printer so see how it fits. It should be snug but NOT tight. If it is tight at all just use the razor and shave here and there until it fits- just a little at a time! If it is too loose then you will never get an identical print when printing on the disks. It needs to be near perfect of you will have a lot of trouble consistently aligning the printer to print correctly on the disk.
That's it, feel free to ask questions.