To make a flight case, gather your materials, and build a plywood box. Cut outlines for recessed latches, hinges or handles. Cover the corners, edges and transitions. Install hinges, latches, handles and casters.
- Gather your materials
For tools, use an electric drill, a jigsaw and a pop-rivet wrench. For materials, you need plywood, closing extensions, "L" extensions, butterfly latches or drawbolts, ball corners, hinges, handles, L-brackets, dishes, thin nails that measure 20 to 25 millimeters and casters. Your materials depend on the chosen design of your flight case.
- Build a closed plywood box
Build a closed box out of plywood with glue and the thin nails. The nails hold the box together while the glue sets. Cut off the lid. Cutting the lid at this time ensures that your box has a secure, well-matched lid.
- Paint the box
Paint the box with a protective paint. Use a black polyurethane outdoor paint to prevent scratches and damage.
- Cut outlines
If you are using recessed latches, hinges or handles, cut out outlines for these items on the box. Account for the depth added by any closing extrusions you are using.
- Fit the closing extrusions
Cut the closing extrusions into 45-degree angles with a miter saw. Make a total of 16 cuts for a case with a top and bottom enclosure.
- Cover the edges, transitions and corners
Line the edges with L-extrusions. Use two pop rivets every 6 to 8 inches. Secure the case closed with a ratchet-strap, and round off the edges under the braces. Cover the transitions from the closing extrusions to the edge, and line with L-braces. Cover the box corners with ball corners.
- Add hinges, latches and handles
Pop on the hinges, latches and handles of your flight case. If your case is very large, use rivets along the closing extrusions.
- Install casters
Install casters to the bottom of the case using bolts to enable your case to roll. Use self-locking nuts to prevent the casters from loosening.