Progress on the guitar flight case. The making of this would have been much easier f I had know what I was going to do with the hardware BEFORE I started. Now that I have the hinges, latches, and handle, I determined where they would be attached and then had to install more substantial attachment material for the screws than the pink foam which is between the fiberglass layers. Once that was remedied I completed the inner portion and got that installed. Now I can paint the case, install the linings and the box that goes between the inner portions, and then get the hardware on.

 

 

 

 

 

My client supplied a tracing of his guitar, in this case a Martin 0000.  I'll use this to layout the interior.  But for now the task is to apply epoxy and microballoons to the exterior, sand it flush, and cut the lid off.  To cut the lid I will use a cut off disc set in the drill press and the case will sit on a panel clamped to the drill press table.  As I pass the case past the cut off disc it will make a cut at a uniform height and in a straight line.

 

 

Awhile back a local musician asked me to make up a fiberglass flight case for his guitar.  For many years Calton Cases out of Calgary had been the "go-to" case for travelling musicians.  Sadly, with new ownership, quality and customer service tanked.  So with this in mind, the request came in.  You can see the Calton case at the bottom of this post.

I decided to simplify the shape for a variety of reasons, partly construction, but also providing more interior space within the same overall size.  I also decided to make it glass over foam, in this case 1/2" Pink insulation foam.  The inside will be glassed as well making it a foam core structure.  The foam is glued together with regular woodworking glue.  While not a very strong joint, it is strong enough to hold it while sanding and glassing.  The foam is kerfed where it needs to bend around the corners.  Simple packing tape is enough for clamping.