There are several methods to build a flight case for different applications. Some of them are discussed below:

How To Build A Dj Flight Case?

Here you will learn about the tools, parts, and how to get started with the construction of a Dj flight case. Before construction begins, the first thing you should know is the right tools you will need.

1. The tools

There are some tools you will need to build a Dj flight case, such as:

• Hacksaw, jigsaw, or circular saw.
• Electric drill.
• wood-type pop rivets.
• wrench
• miter saw (for cutting accurate angles)

Electric drill

2. The parts

After you have learned about the tools, it is also essential to understand the different parts of the flight case you will be constructing. Here are the parts of the case.

• Panels:

You will need 9.5 mm (3/8″) plywood, either pre-laminated or plain, for the pieces. Although pre-laminated is costlier, it is simple and long-lasting. When painting over regular plywood, you can try to use polyurethane-based coating to get  better results.

You should also be aware that MDF is unsuitable for flight cases; instead, choose plywood, which is lighter, more lasting, and more resilient to dings and dents, dampness, and scratches.

• Close extrusions:

Close extrusions are placed between the case and lid to make a closed case.

 closing extrusion

• Hinges– You will need hinges, and if you are using a removable lid‌ every 4-6 inches, you have to use one hinge. Use about four hinges on a 19 wide case.
• Handles– A recessed sprung handle may be the best option when picking handles for your DJ flight case. They’re spacious and strong.

 A handle

• Corners– Use ball corners whether they are stackable‌ or not. Just make sure they are in the right place.

You could use two prongs or or L-shaped brackets for the lids.

• Latches– You can use surface-mount latches because they are easier to install.

You can try using recessed latches, but they will be difficult to install and easy to break the extrusion location.

• Edges– Use 30 mm size “L” or “single angle” extrusions used for edge lining.
• Brackets– L-brackets, also known as cabinet braces, which is used to conceal burrs and sharp edges on closing extrusions.
• Dishes– Dishes are used for the installation of switches or cable sockets
• Caster– If you require casters, choose a braked swiveling variety. For heavy and rugged use, consider a ball-bearing wheel.  

 Caster

• Rails– When choosing your rail, consider going for 19 racks used to slide the rail system.

Steps on how to build a Dj flight case

Now that you know what tools and parts you will need let us look at how to build a DJ flight case step by step.

• Step 1

Starting building a plywood closed box. Although there are different glues in the market, polyurethane or the regular white glue and thin 20 – 25 mm of 3/4 – 1 tacks or nails can be used for this. The nail could keep everything in place when the glue dry.

Please construct in closed box shaped precisely to fit the closing extrusions.

• Step 2

To avoid scratching your work, you will need to cut off the lid before painting.

• Step 3

At this third step, if you are not using laminated wood, you have to paint all the pieces of wood with durable, scratch-resistant paint.

For exterior application, use black polyurethane paint preferably. Although you can use any color of your choice, you can not go wrong with black.

You may get good results by using sandpaper to sand the surface before applying the first or second layer of paint.

Always follow the recommendations on the can to get the best result.

• Step 4

Cut out the outline of dish-type recessed butterfly hinge, handles, and latches, then fit the closing extrusions before fitting the recessed latches. By so doing, you will notice that pre-cutting the dish outlines is more straightforward than making the location extrusion fit properly.

• Step 5

Next, use a miter saw to cut perfect 45-degree angles.

• Step 6

Next, use ball corners to cover the corners.

• Step 7

Next, put the hinges, locks, and handles on the doors. Rivets are only required for huge cases.

• Step 8

Next, you can use casters by bolting them in place with nuts and washers.

Then you can also apply self-locking nuts to keep them from loosening.

When your flight cases will tip over, you can use another base panel to spread the casters wider apart.

If you put casters on quick-release plates, they can be easily removed. At the same time, you could use casters on top of wheeled cases, which allow them could be stacked.  

The DJ flight case is built to be tough and durable, with resistance to various accidents and pressures that can occur during transit.

 DJ flight case

How To Build Your Own Flight Cases?

The first thing you should do is figure out how big the case is. For example, the overall measurements of a product might be 520 x 435 x 400 mm (width x depth x height).

Below is a step-by-step tutorial to guide you in building your own flight case:

Step 1: Get Your tools and parts ready.

The first step is to get all your tools and products parts ready.

 Below are the tools and hardware items that will be used:

• Plywood panels with a thickness of 10 mm: 2x Panel 520×435 mm, 2x Panel 380×415 mm, and 2x Panel 520×380 mm.
• 5x Angle 20×20 (1 m)
• 2x Male aluminum profile (1 m)
• 2x Butterfly clasp
• 215x aluminum rivet D4 x 10 mm (80 is for the bonnet, while 135 is for the base)
• 2x Recessed handle
• 8x Ball corner
• 2x Stop hinge
• 2x Female aluminum profile (1 m)
• 8x Corner reinforcement

Plywood panels

Step 2: Assembly of the woods

Assemble the woods, then cut the panels and make a line of 5mm from the edge.

The thickness is divided by two, so this will be used for the ends. Next, fix small nails around every 8cm.

Remember to glue the panels together before nailing them.

Step 3: Make the cuts.

Draw a line all the way around the box where you want the base and lid to meet.

Then try splitting the box in half with a handsaw. Also, you must consider the location of the latches before cutting.

Woodcutting

Step 4: Prepare the junction profiles.

Next, you will use a miter saw to make 45° angles on the junction profile. After that, make sure the handles are securely fastened.

Junction profile

Step 5: Paint

Next, apply two layers of wood paint after sanding the surface to make it smooth.

 Alternatively, you may consider using pre-laminated panels, which are also available, but they are a bit on the expensive side, but you can buy them if you can afford them.

Step 6: Fix the aluminum profiles

After the box has been painted, you can put it together by riveting the following profiles:

• junction profiles
• aluminum angles
• the eight reinforcements
• the eight ball corners

Step 7: Fix the handles and clasps

After that, rivet the two handles together. Before riveting, you can try adjusting the claps on the front “closed hood.”

Step 8: Fix the hinges

Next, you can fix the hinges after closing the hood and securing the hood with claps.

Step 9: Ready to use

Your work is over, and your flight case is ready to go. Enjoy the result of your hands!

How To Make A Flight Case For An Amp?

9mm plywood is used to construct the flight boxes. Also, it is always good to know how much wood you need to buy by drawing a plan.

Here you will learn how to make a flight case for an Amp.

Tools you will need for the construction:

• Jigsaw
• Rivet gun
• Ruler and square
• A couple of clamps
• Bench
• Drill

Once your tools are ready, take the following steps to construct an Amp case:

Step 1: Cutting of the wood

You can use a jigsaw to cut the wood and a plane or sanding paper to smooth out any uneven edges and surfaces.

Step 2: Making of the box

Next, make a box by using wood glue and timber screws to fix the box together.

Step 3: painting

You can paint it any color you choose at this point. However, black is a good option because it looks better and more professional.

Step 4: Fitting of aluminum

Next, you can start installing the aluminum after you finish painting the box.

The aluminum angle will need to be 30mm x the total length of the sides of the box.

Step 6: Work on the corners

Next, use L brace plates for the inner corners of the box.  

You will also use ball corners for the outside corners of the box.

Ball corners

Step 8: Fix latches

Next, you fix the latches to the box. Latches come in different shapes and sizes.

It will help if you are careful when picking suitable latches for the box.

Step 8: Fix handles

Next, fix the handles. You will need to create the space for the locks and handles.

You will need a drill for the holes, and a saw to carve the proper shapes for the handles.