This airline box is for the Rotator Pursuit behind it. It's made of 1" expanded polystyrene laminated (with 3M epoxy) to 4 mm Coroplast (corrogated plastic). The Coroplast is on the outside and the whole thing is held together with duct tape. The hinge for the lid is also duct tape. The box is 67" long and it weighs about 5lbs. This box is a bit overkill and the foam laminate is not really necessery but it sure makes a nice box that I can also lash onto my bike trailer.
I used some scrap expanded polystyrene to make packing blocks for the inside of the box (mostly so the box cannot be crushed).
The box is not to be mistaken for an airline lobster shipping box. Damned lobsters!
I got the idea for this type of box from www.crateworks.com/ who sell a nice bike box made of Correx (a similar material).