How To Build Flight Case and Transport Box

Published 2021-01-20
Building large flight cases and transport boxes is easy and much cheaper than buying them. Hinges, locks, fittings and aluminum rails is readily available at almost all audio / light retailers of equipment for disco, clubs and festivals. I share the tips on how to construct it in a simple way and make sure you get parallel edges that looks good when the boxes are locked together. With so many different rails, hinges and locking mechanisms it is easy to make a mistake and mount something off-center or with distances that does not take aluminum rail thickness into account.

In this video I show you how I built 3 boxes in total at a cost of around 500$, two very large flight cases for my secondary coil and topload. The third box is a cable and equipment box that is just made from the leftover plywood from the two large cases.

Pictures, spreadsheet for weight calculation and discussion of flight case building: highvoltageforum.net/index.php?topic=1398.0

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All Comments (21)
  • The pointer for the total price in the spreadsheet is at a wrong place :( The total is around ~500$ for the 3 boxes.
  • @zaprodk
    Very nice - now i want to make some custom boxes as well :)
  • This is awesome! I want to make a suitcase that looks like a flight case, do you mind posting what kind of materials they are so I can get my list together to get at the hardware store? I gotta figure out how to rivet but I want to make myself a nice one! Thanks for sharing your knowledge!
  • Hello ! How much time did you take to build it, once you had the materials ? Considering building 3 or 4 for large TVs, I'd like to have your bet (as I will need more time still, to add the internal supportive parts for them). Thank you.
  • @LesWheelerBass
    What type of rivets and size are you using? Good work mate.
  • @joshuakelley383
    where did you source all of your hardware for these cases im interested in building some for my personal lighting equipment
  • @shawncarson5930
    Having a hard time finding that thin laminated ply board in the US. Any suggestions?
  • @bakoguy5330
    You have a very unique look and accent. Have you ever thought acting? No homo. Thanks for the video bro, I’m still trying to see if it’s worth the time to build a case for my DJ lighting, this was very helpful
  • Nice video! I wanted only ask you if Is better your solution to built the structure or is better to use casemaker profiles.. Thanks
  • @officialpoa3171
    My son, you all REALLY, should have built shock absorber cases instead, for gear like that!
  • @lit2021
    Cheap? Haha in the Bauhaus store where I live, that concrete mold plywood is 3 times more expensive than regular plywood, because of the waterproofing. :D But it's definitely worth it, because you don't have to paint it or put any kind of faux leather over it.
  • @djdouglas2705
    How much do you charge me for making me one flight case for 2 55 inch tv
  • @SeanBZA
    Would instead of using the nails and wood glue use instead some slow curing epoxy or urethane sealer, along with drilling the holes for the nails, and replacing them with countersunk long thin chipboard screws. Inside you simply wipe the edges of the seams before the urethane cures, on all except for the base, as this is likely to have another base panel inside, so there you can cut the excess flush with the panel after the lid is cut with the saw. Long screws give a lot of rigidity, and using the urethane sealer means the case sections are never going to delaminate, plus you can use the same urethane to bond the aluminium edges on, so they will not come off except after major damage. I have done the chipboard screw thing often, and the failure is the wood breaking, though I do cheat and use fine thread quality drywall screws often, as they will self drill the hole, but even the chipboard screws work well.