All materials were purchased at www.diyroadcases.com and assembled at TechShop.
Step 1: Getting Set Up
A panel saw is incredibly helpful at this point for dealing with large material, and make sure you have a cut list mapped out so that you don't waste material. For the smaller pieces a table saw becomes the better tool for the job. Piece sizes were based off of an interior dimension of the item to be protected plus foam thickness. Round up a hair to ensure that not only does your item fit in the box, but that you can also get it out again.
Step 2: Cutting Extruded Aluminum
Place an uncut piece of U-channel on one of the side pieces, and measure the remainder. Cut four pieces of the double angle corner extrusion at this length and assemble (but do not connect). Now measure the full length of each side and cut the U-channel. While the U-channel will be done with 45º miters, the long dimension (tip to tip) will match the overall length of the case. The next batch will be corner extrusion to connect the sides to the top (or bottom) of the case. Measure from the inside edge of your existing set up to determine these dimensions.
Step 3: Cut Notches and Pockets
With the notches cut, go back and trim down the aluminum U-channel to match.
The handles for this project were surface mounted, but if you want to do pocket handles mark the location for holes and drill out each corner with a bit large enough to fit a jig saw blade inside.
Step 4: Attaching Corners (part 1)
While a hand rivet gun will technically get the job done, a better quality tool can be worth its weight in gold here. If you can get a pneumatic riveter, now is the time to splurge. Otherwise, if you are doing more than one case be prepared for your arms and shoulders to hate you.
TIP: Test drill holes in scrap material to find the absolute smallest drill bit that will still allow a rivet through. The snugger the fit, the less likely a rivet will blow out (those are a pain).
Step 5: Attaching Corners (part 2)
Step 6: Other Hardware
When attaching the hinges, assemble the case in the closed position and align the hinges along the seam between the two parts. Optional: you may secure the two parts with straps to ensure they don't shift. Slot a rivet in each corner of the hinge and carefully test to ensure the lid moves as intended. Drill out the remaining holes and secure the rivets on the bottom half. While closed, carefully rotate the case so that it stands up like a book, and attach the other side of the hinges.
Like the hinges, have the case in the closed position when you add the clasps. If you mess up the pockets for the clasps, don't worry. A small piece of sheet metal patches everything up nicely.
Slap on some handles.
Step 7: Foam Interior
Use 2” foam for filler material where you need to support irregular shaped objects.
Step 8: Label
Material Shopping List:
- ABS laminated plywood
- Extruded aluminum for corners
- Extruded aluminum for mated faces
- Edge reinforcement (flat corners)
- Corner protection (ball corners)
- Rivets and washers
- Foam padding and adhesive