Thank you for joining me for today’s post on How to Make Custom Size Boxes. Over the years, I’ve spent plenty of time (and card stock!) trying to perfect the art of box-making. While there have been a few successes, most attempts ended in frustration. Then, in 2022, I discovered a game-changing YouTube video by Donna Griffith, Stampin’ Up! trainer. Her tutorial completely transformed the way I approach crafting and gift-giving. Although I’ve written about this technique before, today I’m excited to share two practical, real-world examples to inspire you.
The Worksheet
To make my life easier, I created a worksheet to ensure I never forget the formula Donna shared. I’ve saved it in my Google Drive so I can share it with you. You can access it here: Any Size Box Worksheet. While the worksheet is pretty straightforward, I’ll walk you through it step by step in this post.
Example #1: 3D Card Box
To create our box, we need three key measurements: the width, height, and depth of the item. For my first example, I’m making a box for the 3D Christmas Rose card we created together last week. The card is A2 size, measuring 4.25″ x 5.5″, with the rose adding a height of just under 0.75″. To ensure the card has room to move and make it easier for the recipient to remove, I’ve adjusted the dimensions slightly. As shown in the example below, I’ve added an extra 0.25″ to each measurement for a more practical fit.
The key to a perfectly fitting box—and the main reason I created the worksheet—is to remove 1/16″ from two adjacent sides of the box bottom. This adjustment ensures that, after scoring, the box bottom will nest neatly inside the lid for a flawless fit. Another important measurement to consider is how far down you want the box lid to extend. I like leaving some space at the bottom of the box for a better grip when removing the lid. To achieve this, I typically make the sides of my box lids about 1/4″ to 1/2″ shorter than the box itself.
Assembling the Box
Assembling your custom-sized box is easy and straightforward. Start by cutting the flaps. I prefer to cut these flaps from the short sides of the box. As shown in the image below, I cut along the vertical score line up to the horizontal score line. To reduce bulk, I then trim away a small wedge of cardstock. Once the flaps are ready, fold along all the score lines and burnish them for crisp, clean edges.
To secure the box, I like to use a combination of Scor-Tape and Art Glitter Glue. While you’re free to use any adhesive you prefer, let me explain why this duo works so well. Scor-Tape provides an instant hold, keeping the box together right away. Adding a layer of glue on top gives you a bit of flexibility to adjust the flap position before the tape fully adheres. This combination prevents the flaps from ending up misaligned, which often happens with double-sided adhesive alone. On the other hand, using only wet glue can be frustrating because of the longer drying time. In today’s example, I did need to add a bit more glue to two of the corners for a perfect finish.
The Finished 3D Card Box
These steps resulted in the perfect-sized box for my 3D Christmas Rose birthday card. As shown in the pictures below, the box bottom has a convenient 1/4″ edge to hold onto while opening. The card also has just enough room to move, making it easier for the recipient to remove. I chose to decorate the lid to partially match the card, but this step is entirely optional and can be tailored to your preferences.
Example #2: Card and Envelope Box Set
For our next example, I’m creating a box for a set of 10 mini slimline cards and envelopes. Using the worksheet again, I’ll calculate the exact measurements needed. To determine the width and length, I measure one envelope, and for the depth, I stack the cards and envelopes and hold a ruler behind them. In this case, the stack is about an inch high, as shown in the photo below. To ensure a comfortable fit, I’ll add an extra 1/4 inch to the depth, just as I did with the previous box.
Below are the final measurements for this box. Don’t forget to remove 1/16″ from the box bottom to ensure it fits perfectly inside the lid.
Here’s the finished box for my set of 10 mini slimline cards and envelopes. They fit perfectly, with just enough room to move and easily remove them. I decorated the box lid to match the style of the cards, though you might notice a slight size difference in the design. That’s what happens when you accidentally cut directional paper the wrong way—oops! Oh well, the main idea of the cards still shines through!
The Finished Boxes
Thank you for joining me for today’s How to Make Custom Size Boxes post. I couldn’t be happier with how these boxes turned out on the first try! Before discovering Donna’s video, I would have gone through at least three attempts to get the sizing right. Now, the possibilities are endless—as long as your paper is big enough! For larger projects, like the 8″ x 10″ busted canvas I boxed recently, you can even use poster board to get the job done. Don’t forget to download the free PDF worksheet to keep handy for all your box-making needs. Have a wonderful week, and I’ll see you back in the craft room soon!
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