Making a Casted Aluminum Safe Case

I’ve decided to make a case for my camera and its accessories. I wanted it to be aluminum casted and of course safe. Therefore, according my plan, it should be very durable.

Step 1: Decorative Plastic Foam

I made 2 patterns using decorative plastic foam. The thickness of material was from 3 to 6 mm (0.12-0.24 ins). As aluminum scrap I used cans, pipes and some other aluminum things. The first casting failed because the mold started leaking somewhere on the bottom. Therefore, I had to remake it.

Step 2: Remaking the First Part and Pouring the Second

The second and the third parts were good enough.

Step 3: Fixing Latches and Hinges

The next step was to drill holes and to fix latches and hinges. In addition, I decided to make stainless steel cover plates to fix the sides curvature.

Step 4: The Case Interior and Exterior

I glued polyethylene foam with polymer adhesive. To cover the outer surface I used plastic sheets.

Step 5: How to Use the Case?

This case could be used for a camera and accessories, for some tools, a gun and so on...

Step 6: Durability Test

The safe case (first damaged part) passed the test! I threw it from 3 meters (9.8 ft) high. No damages!