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Well, I'm not a boxer, but have run several deals in the bazaar and have had to ship out several multi-book orders. I am one of those people who can't wrap presents to save my life, so I have never used the PBS wrapper, just the address label part only.
Yes, boxes do work wonderfully. Old cereal boxes, shoe boxes (if you use enough tape). If you want to use the bubble mailers, I have found that the 9"x12" and the 10"x15" work really well for orders from 3-7 books(depending on size). If your books are relatively the same size, and you can stack them together in a cube or rectangle shape, try wrapping them in plain plastic wrap or a plastic bag of some time and then wrapping the whole bundle in an old paper grocery sack.
Some people also use the Tyvex mailers to do mulitiple book orders. If you use these, just make sure you tape the package so that there are not corners hanging out to get caught in the PO machinery.