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@edmundro
The box would definitely be sized to match the bike, both her mixtes have v short headtubes which only leaves about 8" between top of mudguard and top of handlebars. Would shape a channel in the base of the box so the mudguard can be nestled/mounted there for additional support. A front rack would raise it up a small amount which wouldn't really be an issue but would like to keep it neat. Looking at the bike the dimensions would be 16x10x8 which would be fine for handbag, locks, wine etc.
Box will probably be made from 12mm waterproof birch ply. It has really thin layers so tends not to warp and the endgrain is quite attractive. I can cut blind dovetails by hand but unless I end up using proper timber I'll just go for something quick and strong. Struts will be pretty straightforward as well I'm sure.
Obviously mounting a box to a rack is the ideal but cost is an issue, and Liz simply doesn't ever need to carry anything that large on her bike! I might treat myself to a big front rack for my Long haul trucker but I'm in no rush.