Whilst looking for parts to make a flightcase, I happened across a Dutch supplier "CaseBuilder.com", who offer a rather clever website to design your case exactly as you want, and then supply a FULL kit to build it up. The case is roughly a 1' x 1' x 2.5' (30 x 35 x 75cm)
Delivery took less than 4 days from clicking "send order", and I was very pleasantly surprised by the quality of everything,.
Step 1: Design
Here's a screenshot of the design in progress.
...and the build instructions.
Step 2: Delivery
Every panel is lettered and numbered for assembly.
Step 3: Assembly and Tools
Everything comes in the pack - even two twist drills. All you need to assemble everything is a good electric drill and a pop-riveting tool- ideally an airpowered one. I used a Sealey SA31 riveter.
The instructions are very clear. All the metal parts are predrilled, so all you have to do is align the rails with the panels, drill, then rivet. You have to be very careful to make sure the panels are snug against each other BEFORE you drill. Its a one-time thing.
The whole assembly took around 2 and a half hours, but I'll be faster on another one. At this size, another pair of hands would have been nice, but not vital.
Step 4: Finished Box
All in all, the case cost around 220 USD, delivered. How it fairs next month in air-freight, we shall have to see. Yes, it might have been cheaper to buy it as components, but I think the finished quality is excellent