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make a frame out of wood, go to www.usplastics.com and buy some high density polyethelyne (hdpe). put it in the top with plywood under it, and attach it with liquid nails. put pvc tubes or metal down the sides. talk to winterkid33, he had an article or something on how to make one
I actually find that counter sinking screws to attach the topsheet works better. I counter sunk and then I melted wax into the hole to fil it up and sanded it smooth.
And, to make my flat box, I just used an old plastic Bingo/Hearts sign from a Kiwanis club that didn't need it anymore.
Another thing that works is this stuff called concrete board. Its pretty much that stuff they use to make the frame for concrete molds. The top is super smooth and slippy so that works great. Just check out your local construstion site dumpster or look around on the ground. They are gold mines for that sort of stuff.