I have a similar box for a guitar and it's disassembled neck. It's got about 4"-5" tall, and about .5"-.75" thick wooden walls around the perimeter, then larger posts in the corners that the sides are screwed to. I just used a staple gun and Elmers glue, but I bet a glue gun would work even better. I glue and staple the cardboard around entire side, then glued and stapled just the long edge of the side that opens. I use packing tape to close the flap, and don't tear it off when I open it. I just slice along the edge and tape over it again the next time. It has 1" foam top and bottom, and a foam insert that has a cutout of the guitar and neck. I've shipped it all over the place, and feel really comfortable that it will always survive. It's about 4-5lbs light. Cost me about 5 bucks to make. > if you have much of a DIY low budget mind, you could try my favorite method: > I know this sounds totally silly, but I have had good luck making my own travel cases. I use - ready for this? - cardboard! It really works well! All you need is a couple of good strong cardboard boxes, some good packing tape, a bit of hot glue, and a sheet of packaging foam. The foam I use, I get from my shipping dept. at work, and is about 2" thick and cuts cleanly with a steak knife with no mess.