Guitar Case
Welcome to the 'bonus' blog entry page!
After just over 2 months of build time on the Telecaster, I still have enthusiasm to continue to make something, and a long list of project ideas still on the table (amongst them a pedal board/case, an overdrive pedal, a tube amp and a 12" amp speaker cabinet). Having taken several guitars from place to place while playing with other musicians, it was clear that I did not have a reliable case to protect my instruments as they 'traveled'. A good guitar case was a necessity and I figured I might be able to build a nice one. A really cheap hard-sided case is still in the $60-75 range, and decent ones roughly $150-200, or you can pay even more. I did not build this case to save money, although mine cost $114 in materials (some of which resulted in leftover scraps I am using on other projects, making those materials 'free'..!).
As usual, I started with research including guitar case designs for inspiration (and my goal was to end up with a case that looked standard in dimensions and aesthetics - otherwise appearing 'store-bought'). Some blog and YouTube video checks later I was ready to purchase the materials and get started. I'd decided on a standard rectangular case, with rounded edges and a profile as low as I could get it. I measured all my guitars and calculated that one case could fit them all as none varied in the meaningful directions by more than 1/2". Using 1" foam I would make up any remaining space for a snug fit. 1" foam turned out to be a way more snug fit than I'd planned as it does not compress that much where the body rests on it; fortunately I had half a sheet of 1/2" foam left over from another project and substituted the 1/2" just in the body base.
Other materials included plywood and velvet, plus various functional hardware (handle, latches, hinges and corner pieces). Some located at specialty speaker/audio shops and others easily sourced locally. The last important element is the covering. Speaker cabinets and many cases such as guitar cases are covered with a tough, synthetic leather-looking fabric called Tolex. There are substitutes, but I wanted something authentic and which would not lead to other potential issues such as stretching or tearing, etc. And the prices for Tolex are reasonable. I also hoped to have a little left over for my pending pedal board project.....
First step - make a box. I got the idea from a video where the guy used a table saw to cut the box into two pieces for a lid and bottom. Not having a table saw I thought I would risk a bad cut by doing the same using a hand-held circular saw. Thrilled with the outcome (really). The circular saw has an extended arm (guide) with ruler marks on it - which are surprisingly accurate - and by carefully maintaining a flat saw running along the edge of the 'arm' set to the desired lid height I was able to cut the four sides of my rectangular box into two halves. The lid height (or depth) is 1/3 that of the bottom. The latches fit this way and also the handle can then be screwed directly in the middle of the bottom (taller) side of the case for balance.
The middle support piece was measured to the inside dimensions, and a notch was cut out with a jigsaw to provide a cradle for the guitar neck. This was measured for position and glued in.
Then it was time for the trickier steps of foam and velvet fabric measurement as well as covering the case with Tolex. I started with the Tolex as the edges need to be glued down inside the box so that they are covered by the foam and velvet pieces. I used another piece of heavy fabric to test out several corner folding ideas before cutting and gluing the Tolex, since I wanted to minimize bunching of thick fabric (so the corner caps fit well) and make aesthetically good corners. These steps went fairly quickly and I soon had two case halves covered in black.
Using the inner case as a guide I measured and cut foam. The 1" foam proved too thick and dense to use under the body so I was fortunate in having spare 1/2" foam lying around (motorcycle seat, the topic of another blog...!). The velvet was cut to larger than the foam and carefully glued with spray headliner adhesive and folded under (this will be pressed into the case and not visible.
The pieces all made, I was able to cover the middle support with foam and then a layer of velvet. The three foam inserts were placed in their spots and the case was almost done! Just hardware now, consisting of eight corner pieces, three hinges, three latches and a handle. A little tedious with a screwdriver (literally over 50 tiny little screws!) but got it done in an hour or so with the help of a couple of long clamps to keep the lid aligned with the bottom. One side note, the handle is slightly off center for a reason - using a small barbell I balanced the case including guitar to find the middle balance point. The handle was fastened here so that the case remains horizontal when held (the body of the guitar being heavier than the neck end).
And we're ready for a test! The finished case, with Fender Stratocaster nestled safely inside.....
After just over 2 months of build time on the Telecaster, I still have enthusiasm to continue to make something, and a long list of project ideas still on the table (amongst them a pedal board/case, an overdrive pedal, a tube amp and a 12" amp speaker cabinet). Having taken several guitars from place to place while playing with other musicians, it was clear that I did not have a reliable case to protect my instruments as they 'traveled'. A good guitar case was a necessity and I figured I might be able to build a nice one. A really cheap hard-sided case is still in the $60-75 range, and decent ones roughly $150-200, or you can pay even more. I did not build this case to save money, although mine cost $114 in materials (some of which resulted in leftover scraps I am using on other projects, making those materials 'free'..!).
As usual, I started with research including guitar case designs for inspiration (and my goal was to end up with a case that looked standard in dimensions and aesthetics - otherwise appearing 'store-bought'). Some blog and YouTube video checks later I was ready to purchase the materials and get started. I'd decided on a standard rectangular case, with rounded edges and a profile as low as I could get it. I measured all my guitars and calculated that one case could fit them all as none varied in the meaningful directions by more than 1/2". Using 1" foam I would make up any remaining space for a snug fit. 1" foam turned out to be a way more snug fit than I'd planned as it does not compress that much where the body rests on it; fortunately I had half a sheet of 1/2" foam left over from another project and substituted the 1/2" just in the body base.
Other materials included plywood and velvet, plus various functional hardware (handle, latches, hinges and corner pieces). Some located at specialty speaker/audio shops and others easily sourced locally. The last important element is the covering. Speaker cabinets and many cases such as guitar cases are covered with a tough, synthetic leather-looking fabric called Tolex. There are substitutes, but I wanted something authentic and which would not lead to other potential issues such as stretching or tearing, etc. And the prices for Tolex are reasonable. I also hoped to have a little left over for my pending pedal board project.....
First step - make a box. I got the idea from a video where the guy used a table saw to cut the box into two pieces for a lid and bottom. Not having a table saw I thought I would risk a bad cut by doing the same using a hand-held circular saw. Thrilled with the outcome (really). The circular saw has an extended arm (guide) with ruler marks on it - which are surprisingly accurate - and by carefully maintaining a flat saw running along the edge of the 'arm' set to the desired lid height I was able to cut the four sides of my rectangular box into two halves. The lid height (or depth) is 1/3 that of the bottom. The latches fit this way and also the handle can then be screwed directly in the middle of the bottom (taller) side of the case for balance.
Using the inner case as a guide I measured and cut foam. The 1" foam proved too thick and dense to use under the body so I was fortunate in having spare 1/2" foam lying around (motorcycle seat, the topic of another blog...!). The velvet was cut to larger than the foam and carefully glued with spray headliner adhesive and folded under (this will be pressed into the case and not visible.
The pieces all made, I was able to cover the middle support with foam and then a layer of velvet. The three foam inserts were placed in their spots and the case was almost done! Just hardware now, consisting of eight corner pieces, three hinges, three latches and a handle. A little tedious with a screwdriver (literally over 50 tiny little screws!) but got it done in an hour or so with the help of a couple of long clamps to keep the lid aligned with the bottom. One side note, the handle is slightly off center for a reason - using a small barbell I balanced the case including guitar to find the middle balance point. The handle was fastened here so that the case remains horizontal when held (the body of the guitar being heavier than the neck end).
I since installed a third latch in the middle since these photos were taken, as well as little rubber feet on the hinge side.
ReplyDeleteAnd, since built a second case with nickel hardware and a silver/grey/blue velvet interior. I also added a storage compartment in the second case for cables, strings, etc.
ReplyDelete