At a craft store, you can get something called a "bone folder," like this:
https://www.youtube.com/watch?v=0M7xgVweyEM
Used for adding nice creases to thick cardstock
godzilla, I had that same problem, to a lesser extent, with the fold corners cracking and turning white. Since my print was already close enough to black in most places, I just used a sharpie to VERY carefully run along these edges and make them black again. You can't notice it in person.
In general, to avoid that cracking when folding thick paper just use a ruler and a dull edge (like the back of a scissor blade) to run along the reverse side of the crease over and over and over before you try folding it. Then fold against a straight edge.
Another trick I used: I added in these trapezoidal tabs shown here:
If you add those tabs, filled in with black, then fold them inward into the box, your open end will have nice rounded front edges for the blu ray cases to slip into smoothly.
Here are the steps I used to actually create the blu-rays:
1. Acquire a film in .mkv format
2. Use MKVExtract 2.2.2.9 to split this file into its video, audio, and subtitle tracks (~30 seconds)
3. Use tsMuxer 2.6.12 to repack these tracks into a Blu-Ray .iso (~30 seconds)
4. Burn the .iso to a blu-ray disc (~10 minutes)
The result of this raw process is that there are no fancy menus or anything, which I felt would sort of spoil the experience. You put the blu-ray in the player and it begins the film immediately. But there is also no compression or re-encoding involved, so zero loss in quality.
For those just above me who are asking about commissioning someone to assemble a box set for them -- I DO have the extra materials lying around to make three more box sets. But I am also extremely wary of having a new asshole ripped open by 20th Century Fox / Disney to the tune of hundreds of thousands of dollars for selling copyrighted merchandise. So, ah, PM me and we can work something out, maybe.
I've PMed Spheretronic asking for the source files for his covers and the box set -- with his permission, of course, I'd like to do a little personal tweaking of the text (kerning and brightness and so on).
I just wanted to thank everyone here, Harmy especially (obviously), for this project. I assembled a box set using Spheretronic's art and gave it to my dad, who was born in '67 and saw every OT episode in theaters on opening day. He was absolutely blown away by the project, he loved it. Here are a few images of the box set:
Higher-res links:
http://imgur.com/YQMHSOL
http://imgur.com/kqljUkM
http://imgur.com/cggZSV5
http://imgur.com/HKTiqMy
I know my folding isn't perfect -- this was my first ever papercraft project. If I did it again I'd be able to do it much more cleanly.
Also, I know the print job isn't perfect. Shockingly (or not?) Fedex Office's printers wouldn't accurately reproduce all the colors, at least nowhere near as well as Spheretronic's original post. The print job was only like $5 total though, so I can't complain too much.