What size card stock did you use to print out the outer box set?
Is it 8.5 x 11? Or bigger? did you go to a print shop to do this?
I constructed the box first out of black chipboard connected together with paper tape. Then I printed the images on glossy 8.5 x 11 photo paper. I printed the front and back separately. After cutting them out with an X-acto knife, I used a spray adhesive on the back of the paper to attach them to the thick cardboard box.