I needed to ship a gift and I couldn't find the right size box for it so I thought this would be a good time to make my own. I made inner and outer boxes to protect the gift in transit
Step 1: Decide What You Need
I needed a box 14" long by 9"x9". So for this I need cardboard (14+9+1)24" long and (9x4+2) 38" wide. I cut the cardboard an inch long so I could fold the flaps and just trim the overlap and the extra 2" width is for a glue edge. For this I cut open a good (but way too big) box and laid it out on the floor
Step 2: Folding and Cuts
Using a straightedge, I folded the cardboard every 9" the 24" way to get the 4 sides. The extra 2" at the end is for a gluing edge, if there is a coating on the cardboard, try to peel it off where the glue will go. Lay the cardboard flat again and on the folds measure up half the distance of the ends (for me 4 1/2") and cut slits on all the folds on both ends. There was a cut in the cardboard from the original flaps but once the box is folded it won't matter.
Step 3: Gluing
Fold the box back together the long way and glue the 2" lip down to the side. I used gorilla glue because it was the best glue I had here for cardboard, just use whatever will work for you as long as it is strong enough. Once the long seam was dry, I folded the one end together and glued and clamped it as well. Once the glue set again, I packed the gift into the 2 boxes with paper packing, then taped and glued the end shut