Find some business in your town that prints out banners and election signs. The raw banner material usually comes in a roll with a long, heavy duty cardboard box. I use that for 40" straights. For smaller stuff, I get a double wall cardboard box (Not of asian origin, the cardboard has a very low fiber content). I glue all the flaps shut, turn the box on its shortest side and cut off the depth of the size of box I want from the two ends. Basically the bottom of the new box was originally the two short sides. If I need increased strength on the walls, I just glue more card board to the sides.
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