I've been meaning to post a few examples of my trays on my web site but haven't gotten to it yet.
I make trays out of 1/4" plexi. I figure the dimensions. for example If I want a tray to fit 10" x 24" paper I would get a 11" by 25" piece of plexi for the base, 2 pieces of 25" by 2" x 1/4" for the long sides, and 2 pieces of 10.5" by 2" x 1/4" for the short sides. Most plastics places cut to order, so get them to cut for you. It's then kind of like a kit.The glue used is a solvent glue that melts the plexi when applied, and comes in two types- water thin and thick. Ask you plastics place about application. I use both. first make sure everything looks tiight, and adjust with a plastics scraper or sandpaper where necessary. If the plastics place did a good job you might not need anything. Also the thick glue can fix bigger gaps, though it's stronger if you don't need to do it that way.
I start with one long side, glueing it flush to the edge with the water thin glue and pressing hard to get a good bond. remember that the glue is dissolving the layer it touches then hardening again. pressure helps.
then fit and glue two short sides tight to the first piece and flush to the edge. let dry again. then fit and glue last long piece against the two side pieces. when dry you can run a small bead of thick glue around all the seams to make sure you get a water tight bond. Making your own trays takes time, but isn't expensive, and save lot's of room. I've made trays up to 10 feet by 17" and it works great.
try it
Jamie