I'm going to teach you how to make a flight case for a Boss GT-10 guitar pedal, but you could use these instructions to make a flightcase for any purpose you want, and you'll find it's a lot easier than you thought.
Before I tried to build this case I had absolutely no experience doing anything
like this, so if you have no experience than you're perfectly qualified. I have no fancy equipment - the only powered tools I used were a jigsaw and a drill - so you really have nothing holding you back. Before making this project I thought that a flightcase would be very difficult and precise work, but it turns out you can be a lot sloppier than most projects. The pre-made aluminium extrusions cover up all manner of mistakes, so relax, it's going to end up looking amazing.
My case has a patch panel on the back of the inside shelf [pic 3], and a built in cable storage compartment in the lid [pic 4]. It also integrates my wireless receiver so when I set up at a gig I plug the power cable in, plug it into my amp or the house, and I'm done. That's it - my bass case, my pedal case, and two cables - that's all I need.
- A big sheet of laminated plywood, I used 7mm. You could use non-laminated and paint it, but it is nowhere near as strong.
- Flightcase hardware from Penn Elcom
. I'll be detailing what I used as we go through, but there are so many different parts you could use to change the functionality or the aesthetic. I wanted to get the base part of the case (the side with the pedal in) as thin as possible, so that I could still easily hit the buttons with my foot. For that reason I got specific corner pieces and butterfly catches, which I detail in steps 3 and 4.
- Aluminium blind rivets. I used 4.8mm diameter, 9.6mm grip.
- Washers the same size as the rivets.
I haven't given any measurements for the pieces I used because you'll most likely want to customise the box to your specific requirements.
- Power drill
- Mitre block
- Rivet gun