Does anyone have any tips on making your own card box?
Also does anyone have any ideas for a gimmicked card box?

I don't know a way to make a good card box, but if you find a way you could print a playing card on it.
When you hide the printed card and force the card on the spectator it can be used as a prediction or something.

There are a number of features I'd like to see in a magi's card box:

A) tougher, thicker card so the box lasts longer; also slightly wider so as to be able to hold a few more than 54 cards
B) a slightly deeper thumb slot and longer top flap (for retaining or drawing out cards from closed box more easily)
C) a built-in card revelation (or two)
D) a hidden mnemonic for a stack
E) if possible, a well disguised index window (this might not be realistic)
F) if possible, a built in shiner utility
G) if possible, a built in 'retention' flap, false section, or device so as better be able to leave card(s) hidden in the case

I've been playing around with the idea of creating SVG's that I can cut on my wife's craft cutter (Silhouette cameo, it will cut things as thick as cereal box cardboard.)


Boomer

Here's a template designer: http://www.cpforbes.net/tuckbox/tuckbox.cgi
I'm interested in trying this too, if you find a suitable cardboard stock, let me know.

I finally make boxes with a die cutter. They are amazing. Really suggest buying one. Made custom printed like bike boxes. Found perfect card stock at the dollar store.

It would be nice if there is a stylish card box that is waterproof, keep the cards dry, but not thick like those waterproof cases.

You can use standard boxes and apply vinyl stickers with reveals on the sides. Been doing it for a while on Phoenix boxes (Christian sells empty ones very cheap). Plus you can cut a slit on a corner and use the cellophane to hide it (the back design is usually well aligned with the cards inside). For the cutout I suggest a hole punch (diameter 2cm) so you can enlarge a little. I’ve been also experimenting with white vinyl for the front with good results. PM me I can provide some SVG templates of non copyrighted elements.