oojason’s idea of “reusing” an existing box set is an Excellent idea! You can get one dirt cheap @ a Pawn shop, like $5? The recover it with your own designs. I wish I would have thought of that before I make my box sets.
Getting the printout on a large enough paper to glue to the whole box in 1 piece was the tricky part. I used Bristol Board? Depends on how rigid you want the end result to be? Keep in mind the thicker it is the harder to cut & bend.
The nice thing about making your own is once you figure it out, you want to make another, then another!
My first set has a box within a box, my 2nd set was made to look like an old style Film shipping box, with straps.
I screwed up calling the 1977 A New Hope…as it was just Star Wars in 77.
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GOOD Luck. Just take your time & measure, measure, measure!