Here's what you need:
1. Two (2) Priority or Express Mail boxes (15.5" x 21.5") from your local US post office. These are free.
2. Packaging tape
3. Box cutter
4. Pencil
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Signing UpStep 1: Step One: The interior protective envelope
Start by turning the box so that the short side is towards you.
1. In the lower left of one of the boxes, measure and pencil out a 13.5 x 19.5 inch box.
2. Cut along the 13.5" side, removing and discarding the entire 15.5" x 2" portion.
3. On the 19.5" side, mark out a 7.5" x 2" rectangle in the top right, and another in the bottom right.
4. Cut out those 7.5" x 2" rectangles, leaving a 4.5" x 2" tongue in the center.



































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along the axes. (I mean plural of axis not of ax{e?}!
I hate the English language at times!
Anyways that would help against bending, though lightweight rigid plastic might be hard to come by, unless you collect "random" stuff
(like my workspace does!)
On a side note, I wasn't aware that the USPS actually give those boxes for free. Thanks for the info!
(Wonder if they would mind me taking a bunch, for "projects")