DIY road case (flight case) - easier than you think!

[@Terrible_Peril]

I like seeing non-industry peeps do a case build like this, and do it so well!

[@ournextmake]

Thanks so much! This was an incredibly fun build, and we learned a lot along the way. We'll definitely make another one in the future!

[@tankthebiker]

Thank you for building it with the correct hardware! The roadie in me is happy!

[@DeputatKaktus]

Thanks for the inspiration! Last year I also built myself two flight cases. One to transport an Amiga 500 and a desk riser (built from 2020 aluminum profiles and phenol resin plates), the other one as a pre-wired 10” 9U rack unit with an Intel NUC and a RPi with Retropie, networking and Blinkenlights in it. It has a mains connection, a junction box for two 10” rack mount powerstrips and a separate, hardwired 5V PSU for the blinkenlights and an LED light strip in there that is controlled by an ESP32, which also links up to the inbuilt WiFi network. That case I just need to put on a table, take off the front and back lids, set up the screen (stored in one of the lids), plug in power, pull out a mouse and keyboard and I am off to the races. I have a GL iNet router in there so I even have internet connectivity. Pretty neat if I say so myself. And it is evolving. It is an absolute beast in terms of weight. Same for the Amiga case. And the next time I build a case, I will make sure to get a pneumatic rivet gun. I am not going to torture myself like that again. 😅

[@ournextmake]

We're glad you liked our build. Thanks for sharing the details of your flight cases. They both sound epic!

[@leisureshoot]

I occasionally order these for work. They aren't terribly expensive, but this is an awesome build. One thing I like about the place I order form is they cover the inside with carpet, which covers all the hardware to avoid scratching equipment and hands. They cover the outside with some sort of hard vinyl-like black coating that nothing sticks to, which keeps it looking clean an new. Over the past several years we've experienced about 5 shipping incidents where the shipper puts their forklift forks through the side. I have either patched the holes with a steal plate and bolts and lock washers, or ordered new cases.

[@ournextmake]

That's really cool. Thanks for sharing. Covering the inside is a great idea. The rivets and other metal bits can certainly scratch things up. We've seen carpet applications as well as custom cut foam to hold things in place. We just love how customizable these cases are.

[@nevillecreativitymentor]

QUICK ... CLEAN ... NEAT. Thank You.

[@ournextmake]

We're so glad you liked it!

[@compnmuzac]

Thanks for the tips. I'm currently restoring an Anvil case from rotted foam and I am going to add casters as per your design!😃

[@ournextmake]

That's awesome! These are so much fun to work on. Good luck with your project!

[@IrregularShed]

Really slick stuff, thank you for showing it! I just wish I had a workshop where I could make something like this...

[@ournextmake]

This was a fun build... we're glad you like it! If you don't have a workshop of your own, we'd highly recommend looking for a nearby makerspace. It should be able to give you the room and the tools you need to make the projects on your list. ...and you'll likely meet some awesome like-minded folks there too!

[@clemmcguinness1087]

Tidy work, good design

[@ournextmake]

Thanks so much. We're glad you liked it :)

[@jetjamesc2857]

Great work! What size of rivets did you use?

[@ournextmake]

We're glad you like the build. We used 3/16" diameter by 13/16" length rivets for most of the build. We did use 15/16" long rivets in some locations where we had a thick stack of components to join. Here's a link to the 13/16" rivets (you can also find the longer ones on this site) www.diyroadcasesstore.com/6690-pop-rivet-3-8-1-2-wall/

[@timothybaker8234]

Nice project. I’ve always wanted to build one of these.

[@ournextmake]

Thanks! You should totally try making one for yourself and tell us about how it turns out. Good luck!

[@atillakandemir6439]

DO NOT USE A REGULAR WOOD BLADE - YOU NEED A BLADE WITH A NEGATIVE RAKE

[@ournextmake]

Thanks for sharing this advice.

[@alexsouthgate7551]

Brilliant video, thanks! I’d love to make one but I only have basic hand tools (for now!).

[@ournextmake]

We're glad you liked the video. It was a lot of fun to build! We wish you luck when you do decide to make one!

[@ronwilliams621]

DIY ? yeah right ! You guys just happened to have a room full of all the necessary tools to build your 'DIY' cabinet ! LOL !

[@cctknight84]

Do you have any idea if building your own case saved any money over purchasing one? Or is it just that you could customize it to your needs?

[@ournextmake]

Our primary goals were to learn how to build something like this, and to tailor it to our specific needs. The cost of a new unit like this was also on our minds, and I think we did save a little money. We spent about $320 US on the metal parts (this includes shipping and taxes), plus about $50 on the plywood. I think it would have cost at least a few hundred dollars more for a new unit of this size. That said, I have been told that you can find used road cases for a bargain if you look around a bit.

[@studio12archive60]

Great video. I am now inspired to attempt this myself but I would like to use that crinkly aluminium covering that I see many flight cases covered in. Not knowing what it is called I am having great difficulty sourcing it. Can you tell me its correct name so I can find it? Many thanks

[@ournextmake]

We're glad you like the video. We bought all of our hardware from www.diyroadcasesstore.com and they sell case wall material, but I don't think they carry what you're looking for. Are you referring to aluminum diamond tread plate? If not, maybe try to Google "aluminum sheet", or "brushed aluminum sheet", or "aluminum flight case wall material". I hope you find what you're looking for. Good luck making your own.

[@NSPCases]

Hi, you are looking for 'aluminium stucco'. It's available in a thin laminate or pre-laminated to plywood.

[@georgemacdonald5282]

Great video and well explained, thank you from george.

[@ournextmake]

We're so glad you liked it, George. Thanks for the kind feedback.

[@johnpezaris6982]

Using screws instead of rivets would have solved the problems with the corners.

[@gregorymacneil2836]

To frame your case you should have purchased the 1/2" double angle if you wanted to go with 1/2" plywood - The double angles makes sizing and assembling the case so much easier. Solves any issues with the corners. Ideally you would use the 1/4"plywood sheets with plastic laminate and 1/4" double angle to keep the case weight down - This stuff is durable - I bet it is as durable as what you built! I buy these all the time for my equipment - they are not that expensive - I have also purchased used ones at government auctions and downsized them. You can typically buy them at an auction for 1/2 the hardware cost.

[@ournextmake]

Thanks for the great feedback! We were certainly intrigued by the double wall extrusions, but went with the single wall as it just felt a bit more familiar, and aligned with our typical approach for building wooden boxes. We're glad to hear that they make the project go much easier. Also, thanks for tip about the 1/4" ply. Our case did end up a bit heavier than we had hoped, so we'll definitely have to give thinner ply a try for our next build!

[@leisureshoot]

an oscillating tool would have removed that block really cleanly without any plywood damage

[@ournextmake]

That's such a great tip! ...and I own an oscillating tool too. Why didn't I think of it??? I guess the lesson here is to slow down when you're faced with a problem and really think it through. Thanks so much for sharing!

[@leisureshoot]

@@ournextmakeha ha! I way too often rush to fix mistakes, only to make them worse!