Hey toastedzen,
This How To Make Your Own Custom Box might be of interest to you, but it’s only half-way completed.
What I personally have done is to use the Blu-ray cases themselves, all put together as in your picture, to trace my sizes onto the cardboard before I cut.
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Then I made sure to trace the top/bottom first. Then cut the pieces.
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Then I rubber banded the top and bottom pieces and included them in the tracing for the spine so it would be flush with them. Then cut that piece.
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Then I rubber banded all three pieces for the final trace for the front and back sides so they would be flush with the top/bottom and spine.
Here’s a crude MS Paint Sketch to try to make that a little clearer:
It looks like you are using the same size cases I did, so here also are the measurements of what mine ended up being. But I can’t promise those will fit, so probably best to use them just as approximate numbers until you can check them against your actual cases.
Top/Bottom
5 5/16" (137mm)
by
1 7/16" (37mm)
Spine
7" (177mm)
by
1 7/16" (37mm)
Front/Back
7" (177mm)
by
5 7/16" (139mm)
As far as the art goes I found this video guide very helpful, except the part about using large mailing labels. I’m pretty sure the adhesive will breakdown faster than you’d want it to. So instead I will be using rubber cement and glossy flyer paper that is inkjet compatible.
Best of luck!