Cardboard Upcycle: How to Make an Insulated Casserole Carrier

Raid your recycling bin for a cardboard box to construct an insulated carrier for transporting hot menu items to friends, neighbors or family.

Photo by: Sam Henderson

Sam Henderson

Related To:

Materials Needed

  • covered casserole dish
  • leftover cardboard
  • ruler or tape measure
  • pencil
  • utility knife
  • aluminum foil
  • glue stick
  • hot glue gun and glue sticks
  • cloth-backed tape
  • thick rope or braided rope

Create the Base

Measure the length and width of your food dish and add 1 inch to both measurements. Using that measurement, cut five pieces of double-thick corrugated cardboard with a utility knife and a straight edge such as a metal ruler or yardstick (Image 1). Set two of the pieces aside for later. Apply glue stick liberally to one side of one of the remaining cardboard pieces. Press aluminum foil to the sticky surface and trim away excess (Image 2). Repeat for the other side. Add hot glue to one side of two other cardboard pieces, taking care to cover the corners and edges (Image 3). Press the three pieces together with the aluminum-foil-covered piece in the middle.

Create the Sides

Place the food dish, with the lid on, on the base with a scrap piece of cardboard on top. Measure from the bottom of the base to the bottom of the scrap cardboard (Image 1). Add 1/2 inch to that measurement to determine the necessary height of the sides. Cut two pieces of cardboard, with the corrugation channels running vertically, to the length of the base by the height of the sides (Image 2). Cut two more pieces that are the length of the base by the height of the sides minus 1/2 inch. Cover one side of the shorter pieces with glue and aluminum foil. Glue each of the shorter pieces to the taller pieces with the aluminum foil in the center to create the end panels. Use hot glue to attach the panels to the base with the taller sides facing inward (Image 3). Measure the length of the base with the newly attached end panels. Use this measurement and the height of the sides to create two longer side panels in the same way the end panels were created with the outside piece 1/2 inch shorter than the inside piece. Apply hot glue to the edges of the end panels and the base (Image 4). Press the long side panels into place and cut away the notch created at corners (Image 5).

Create the Lid

Create the top of the lid with the remaining two pieces that match the base. Apply glue and aluminum foil to one side of the pieces, then attach the two pieces together with hot glue, ensuring that the aluminum foil is in the middle. Create the end panels first, then the side panels in the same manner as the bottom of the carrier. However, the height will be 1-1/2 inches for the tall side and 1 inch for the shorter side. Use hot glue to attach the panels to the carrier top with the shorter pieces facing inward (Image 1). Cover all exposed corrugation on the edges with cloth-backed tape (Image 2). Cut notches at corners and fold over excess for a clean finish (Image 3).

Create the Handle

Use thick rope or braided thinner rope to create handles. Draw light pencil lines on the sides of the carrier (bottom only, not the lid) to divide the sides into three equal parts. On the outside of the lines, liberally apply hot glue. Press the rope into the hot glue and hold in place (Image 1). Leave enough rope at the top to create a handle that reaches just past the center of the top of the carrier. Cut the end of the rope at the bottom of the carrier. Use hot glue to seal the ends of the rope to prevent fraying (Image 2).

Take Dinner To Go

This handy insulated carrier makes it easy to keep food hot when taking a dish to a potluck or dropping off a casserole for family, friends or neighbors.

Photo by: Sam Henderson

Sam Henderson

Next Up

Halloween Decor: How to Make Creepy Apothecary Jars

Take your Halloween decor to the next level with these easy-to-make apothecary jars made from recycled medicine bottles.

Upcycled Flannel Holiday Gift Wrap

Start saving those empty dry-good containers now to upcycle into festive fabric-clad packages that can be used again and again.

How to Make a Garden Fence From Upcycled Pallets

Keep critters out of your garden with this inexpensive fencing alternative that can also serve as a planter.

5 Small Things We've Bought That Saved Us Money in the Long Run

From products that help curb expensive drink habits to long-lasting LED lights, take a cue from our editors and discover small household items we love, all under $100, that can save you money down the road.

Upcycle an Old Cake Pan Into a Christmas Candle Ring Centerpiece

Got a past-its-prime Bundt or tube cake pan taking up space in your cabinet? In just a few steps, you can upcycle it into a cheery Christmas centerpiece to brighten up your holiday table all season long.

How to Make an Easy DIY Outdoor Movie Screen

Transform your backyard into an open-air movie theater with this easy DIY screen made from PVC pipes and a white sheet.

HGTV Obsessed Episode 19: Tiffany Brooks

In our budget decorating episode, Tiffany Brooks host of $50k Three Ways, talks about projects that add the most value to a home. Then Kelly Wilkniss of the Decorating Tips and Tricks podcast shares creative ways to get high style at a low cost.

5 Things You Should Not Clean With Vinegar

Vinegar is a great, inexpensive natural cleaner for many household items. However, its high acidity can cause damage to metal, stone, rubber and hardwoods. Read on to find out what not to clean with vinegar.

Turn an Old Laundry Detergent Pod Container Into a Moon Planter for Succulents

This trendy, DIY upcycled moon planter is surprisingly easy to make out of an old laundry pod container. No one will believe that this lunar planter came straight out of your recycling!

What's New in Handmade

On TV

Follow Us Everywhere

Join the party! Don't miss HGTV in your favorite social media feeds.