Introduction: Tough PVC Cases for Anything

About: Tall nerd, degree in manufacturing tech. I dabble in everything. Many of my projects in here are pretty old. These days I mainly do 3d printing and run startups- ask me anything!

Ever need a case for something that you didn't want broken? Like making things that are simple, yet indestructible?

It is very simple to make a very tough case out of some PVC or ABS pipe.
I made a gift for my  friend, but it was pretty delicate, so I needed a case to put it in. Looking at the junk lying around my work table, I devised this and built in in about an hour.

Step 1: Materials and Tools

  • Saw, either a hack saw, hand saw, or reciprocating saw.
  • Ruler and marker to make straight lines.
  • Drill
  • Rivet gun
  • Hot glue
  • Knife
  • PVC or ABS pipe, mine was 2-inch diameter, but whatever works
  • Tough foam, or two end caps to fit the pipe
  • Cloth-optional
  • Short screws or rivets
  • two small hinges

Step 2: Cut the Pipe

Cut a piece of pipe to the desired length.

Draw a straight line down the length of it, as shown.

Cut on that line.

Go to the exact opposite side of the pipe, and do the same.

Now, you should have two equal half-shells of pipe.

Step 3: Hinges

Tape the two shells back together. Get your  hinges and mark where you want them to go, and the holes for them. Remove the hinges and tape, then drill the holes.

Attach the hinges with the pin barrels facing outward, using rivets (like I did) or bolts.

Step 4: Ends

Cut four half-circle pieces of EVA foam, or really anything else that works. Shape them, and glue them in the ends to make end caps.

I just hot-glued mine, but epoxy is a lot tougher.

Step 5: "Latch"

Cut a piece of the same pipe you used for the case, about an inch and a half long.

Cut an ark out of the side of this, about a quarter of the total circumference is about the least you can go with. Remember, the less you cut out, the harder it will be to snap the latch on and off.

Step 6: Acessorize

I lined mine with black vinyl. You don't need to.  I also sanded the surface with high-grit sandpaper, to give it a slightly better look.

That's it!

Go crazy with this design, it has tons of possibilities!