I made one for a hedge trimmer out of 1/4" luan plywood, and some fir spacer strips; worked well. Thought about making some for 36" bars to protect in transit (we were removing the bars from the MS660s so that they were easier to store in the trailer).
A number of guys use fire hose, if they have access to it. I was concerned about rusting the bar and chain, since the piece I received remained wet inside for several days after I cleaned it out (was mildewy) - might be different with all cotton stuff?
Anyway, this corrugated plastic is essentially a free material that can be used for a lot of things. Check out the totes / trays that the USPS makes out of them. you could also make a 'fold-over' style scabbard using Velcro, twine, or small bungie loops to wrap around the guide bar, instead of sliding it over the end and catching on the cutters.
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