I am looking for suggestions for a hard sided box for shipping that does not require removing the racks. Any ideas on what to buy and where to get it would be really appreciated.

While having a box that doesn't require rack removal would be convenient, the size of the box would be so large as to put you over the limits of most shippers and/or airlines. I learned...the hard way...that going even an inch over the limit drives the shipping costs from stupid to ridiculous. It more then triples the UPS price for shipping. That's likely the reason you won't find one.

I didn't consider the additional shipping cost thanks for mentioning it. I guess I will have to pull the racks, I was just being lazy.

Amtrak at selected stations.. + I've bought similar at the KLM counter in the NL Intl. airport
to fly Home from Shiphol/AMS. [less current.. was many years ago]

Out here we pack peoples bikes in standard boxes . at most the rear rack is loosened,
unbolted at the bottom, to get low enough to close the Box..
front wheel and rack and fender are removed, , bars stem seatpost pedals, etc.

[i note you got realistic about the packing, and really dropped the big box Idea..

I have taped together a couple bike boxes, to get things to fit, before..

Well you have to pull the handle bars and pedals, the rack is really mo big deal.

I have done this. Works pretty well.

The CrateWorks Pro XC or whatever it's called is a nice box, although you still have to remove the racks. I can get my large LHT inside along with the racks and even a smallish tent and sleeping bag.