Hobie Cat sells the original Toybox (again).

It's $364 Plus shipping + tax, and can be seen on page 31 of the Hobie catalog.(http://www.hobiecat.com/cats/partset.html) It's roughly 10'4" Long x 20" wide x 12" tall and weighs 39 lbs. That's about the best there is in man-made materials. I've looked extensively into chepaer alternatives (ski lockers, etc) with no luck.

My local dealer has one in stock. Maybe they would sell it and ship it to you cheaper because they are kind of stuck with it now (They ordered it by mistake). Contact me directly if you want more info.

If you insist on making your own, only use plywood for the bottom and bend a piece of 1/8" thick gray PVC sheet ($50 for a 4'x8' from McMaster.com) over it. This forms a nearly semi-circular (actually more like catenary arc) waterproof cover. You can make removeable semicircular end caps out of plywood too.



Steve