He's not going to talk about boxes again, is he?
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The outer boxes are a little trickier. They have to be a little bigger than the inner boxes, and come with a double set of top flaps. The 4 foot square flat pieces I have just aren't big enough to make that from a single piece. Digging around my basement at home I had found two collapsed large cardboard boxes and brought them with me today. The first was about 24" x 24" x 13", with large flaps on all sides, top and bottom. I spent some time looking at the large box, trying to come up with the most efficient way to convert it to the shape I needed. Did some sketches, figured it out. The second photo shows the start of that process. Very slow going- can't really just create a pattern, but rather I will be cutting and folding it one piece at a time, essentially wrapping it around the inside box, while leaving just enough space for the protective panels. Didn't get very far today before it was time to quit, but I have a plan, so I should finish this box on my next visit.
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