Rich, my amazing brother, makes our boxes. And he makes them very well. We've had a standing contract with an institution of better learning for a number of years to build over-sized boxes for their print collection. The whole library will move in the not-too-distant future and the orders for these behemoths have become larger as the deadline approaches.
Above, witness our technique for adhering the trays to the cover: cloth-covered bricks...and alot of them. The presses we have just aren't large enough. A fence board is placed inside the tray before the bricks are laid in to prevent an impression.
Here's a little over half the present order; I think it's 28 boxes total. We're using an English Buckram for the cover material, and laser printed labels (on Dove's Gray). The Buckram comes from Adele Kaufman, Inc. in NY---David Kaufman is wonderful to work with, should you be in market.
So these will make it to their assigned books and portfolios tomorrow, and we'll be that much happier for the freed-up bench space.