Introduction: Making of a DIY Flightcase

About: Hi I'm Tanguy from France. I'm mechanical designer for more 15 years, I used to design special machines in the past, now I design and modify electrical low voltage switchboards. I am fascinated by mechanical d…

I have some sound equipment and I needed some kind of box to store my lights and various accessories.

I realized a few months ago a "DJ suitcase" a kind of flight case, with mixer and light dispatching (picture at the end of this project), I decided to detail you the steps of the realization of this new "case".

Step 1: Parts

I had to first determine the size of the box.
Here the overall dimensions are 520x435x400 mm (Width x Depth x Height).

I used plywood panels, thickness 10 mm :
_ 2x Panel 520x435 mm.
_ 2x Panel 520x380 mm.
_ 2x Panel 380x415 mm.

The necessary fixations:
_ 215x aluminum rivet D4x10 mm (80 for the bonnet, 135 for the base).

I ordered the hardware elements on the internet:
_ 2x Recessed handle :
_ 8x Ball corner :
_ 8x Corner reinforcement :
_ 2x Butterfly clasp :
_ 2x Stop hinge :
_ 2x Male aluminum profile (1 m) :
_ 2x Female aluminum profile (1 m) :
_ 5x Angle 20x20 (1 m) :

Step 2: Assembly

_ Once the panels have been cut, lines must be drawn where necessary, 5 mm from the edge (thickness 10 mm divided by 2) which will be used for the ends.
_ Then place small fine nails about every 8 cm where needed.
_ We must now glue the panels, to finally hold them by nailing.

Now we get a fully closed wooden box.

Step 3: The Cuts

_ We draw a line all around the box where we want the junction of the base and lid.
_ Then we open the box in two parts with a handsaw.
_ The locations of the 2 side handles are cut with a jigsaw.
_ Similarly for the location of the latches (note: take into account the thickness of the junction profile for cutting).

Step 4: Junction Profiles

_ Prepare the junction profiles by cutting the ends at 45° (use a miter saw).
Important : They are here temporarily mounted, they are not fixed.

_ Check that the handles are properly in place.

Step 5: Painting

After having sanded the box, I use a simple wood paint in 2 layers.
You can also find panels already laminated but inevitably more expensive, all depends on the end use.

Note that the edges are not properly painted, they will then be covered with aluminum angles.

Step 6: Fixing Aluminum Profiles

Once the box is painted, we assemble by riveting :
_ Junction profiles.
_ Aluminum angles (cut as shown).
_ The 8 ball corners.
_ The 8 reinforcements (at each bonnet corner).

Step 7: Handles and Clasps

_ The 2 handles are presented then riveted.
_ The clasps on the front are adjusted "closed hood" then riveted.

Step 8: Hinges

Once the hood is closed and locked by the clasps, we can present the hinges.

Remember to put the axis between the 2 junctions.

Step 9: Ready to Serve !

The flight case is over.
It will have cost me about 50 euros

You can arrange the interior at your leisure (with a foam coating for example).
On others pictures, my "DJ suitcase" which I spoke at the beginning,
New ones are for a yellow toy box for my son who loves the movie "Back To The Future".

My project inspires you, send me photos of your achievements.

Have fun...