Step 3: Riveting stuff

Drill some holes and rivet those puppies on. You can see I'm using duct tape to hold the extrusions in place while I drill the holes. You don't need to use washers on the inside for these rivets, they will do a very strong job of gripping just the ply. Yes, I was surprised by this too, but I learnt this from a real flightcase maker. If you want to prove it to yourself, get a scrap bit of ply and rivet a scrap bit of L extrusion on. There is no way in hell you're pulling that L extrusion off.

[pic 2] is the box so far, now for the corner pieces. Elcom part 1064 from this page are the ones I used. I put the "feet" part of them at the rear of the case, so when the handle is at the top, it's sitting on the feet.

Hold a corner onto the case and drill the holes out [pic 3]. I didn't use a pilot hole, the corner piece held the drill bit in place. IMPORTANT: For the holes that are going through the locking extrusion, make sure you only drill through one side of the extrusion and not all the way through! The rivet will grip just fine through one side only.

Rivet on all the corners and step back and admire your work. Looking very sharp indeed!!
I was shocked when a national company asked 450 US$ for a little case I wanted, because i needed 2 more a lot bigger, so i tried making the little one, and after learning what it takes I also made the 2 big ones :)<br>
That's fantastic!!! Love the pics, thanks for posting them. :)
great build! Can't wait to try my own!
I was looking into building something like this for a portable booth, you've inspired me to do it like this even more. Just looks more professional ! I'll be sure to post ya some pic's <br>Thanks a million!!!
Can you build this using MDF instead of plywood?
I wouldn't. MDF is nowhere as durable as plywood for the same thickness. It also doesn't handle getting wet very well if you were to spill a beer on your case. With the plastic laminate on it, it might do pretty well, I'm not sure about that. The good thing with the plywood is that if you can find a supplier, you can find it already laminated with the plastic.
Where did you get the laminated plywood for your build? I've been searching the internet and can't find the right stuff. I'm in the process of attempting this but I'd like it to end up as profesional looking as I can make it.
I just went to a company that makes custom flightcases and bought a sheet of plywood from them. Any company that makes the cases or stocks parts for cases will have it.
This is really cool! I really want to get started on it. quick question though: has anyone ever tried to take this through the airport? I Need to know so I can fly out to Canada for a gig and spend an extra $300 on concert goodies.
I've flown internationally with my case several times with no problems. You could install lockable catches if you wanted additional security.
What a great Ible. Just what I needed. <br><br>Steve
Do I have to design my own case and THEN have the total parts cost or is there an individual price list from Penn Elcom so I know how much I can afford beforehand?
What a great job. I had a question about actually using a rivet tool. Never used one, but I've seen stuff online and it looks as if there are different types, and types of rivets. Could you clarify what you use? Also, does the company, Penn Elcom sell directly to consumers? Their site looks like they are a wholesaler. Another thing, would you have a rough estimate as to what this project cost?<br><br>Thanks again. Great stuff. Very inspiring. It's making me want to walk to my garage through the snow and build one now.
Penn Elcom does sell directly to customers. <br>I am one of the salespeople in the Canadian Division <br>When it comes to pricing...it all depends on what you are looking for. <br>There are many options to suit your needs. <br>Thanks! <br>
Just a standard hand rivet gun. It cost me $10 I think. Looked like this one: http://www.ldemporium.co.uk/images/68000C.jpg
Hello. Thank you for posting this how-to! <br><br>I am currently gather and pricing materials for my build. I am a little confused about the lid extrusions and the L extrusions. I understand the L extrusion as that is fairly straight forward, but what exactly does the lid extrusion look like? You have a link, but it just goes to the home page. <br><br>Much obliged!!<br><br>-Matt
It depends on the size of your ply, but choose any of the &quot;Hybrid Location&quot; extrusions on this page. You put one on the lid and one on the base rotated 180 degrees. Since they are the reverse of each other, they lock into each other. I've updated the instructions with a picture of what the extrusions look like, thanks!<br><br>http://www.penn-elcom.com/products/hardware/extrusions/edge-extrusion/58/<br><br>Penn Elcom must have deleted the original one I linked to.
thanks i think build one for my zoom 505 and another for my strat
Good luck! Send me a pic of it when you're done.
Thanks for the ible!
Hey,&nbsp; I'm wanting to build something similar as my pedal board and I was wondering about how you dealt with Penn Elcom, did you order through their New Zealand contact in Auckland, or did you do it straight from their website. I live down in Wellington and I can't find any local suppliers either.<br /> <br /> Diesel Phoenix?<br />
Haha yep :D<br /> <br /> I&nbsp;got most of the hardware from http://www.livesound.co.nz/, and a couple of items plus the audio connectors from http://www.jansen.co.nz/. &nbsp;The L&nbsp;extrusions I&nbsp;just got from Bunnings as it was much cheaper.<br /> <br /> John from Livesound was great, really helped me out and gave me a couple of pointers.&nbsp; They build a lot of roadcases so it was quite cool to have a look around their workshop.<br />
What size are the extruded corner strips?
19mm x 19mm. I got them from Bunnings.
looks like a really, really nice result. if i had money...
Surprisingly it's not that expensive. A commercially made case in New Zealand would be about $350, and that one cost me $120 for the case materials, and about another $60 for the audio hardware. The plywood was the biggest cost at $80. These are all New Zealand dollars of course.

About This Instructable


188 favorites


More by alang: Build a flightcase pedal board
Add instructable to: