I needed a hard box for moving my guitar to gigs.
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There´s not much science, you just need the following:
- MDF wood (or any of your choice)
- Ethylene-vinyl acetate rubber.
- Glue, nails, screws.
- Hinges x 2.
- Few tools: screwdrivers, hammers, scissors, drill, bits and must be forgetting some.
- Sinthetyc leather (for covering the outside)
- Soft cloth for the inside.
- Board of high density foam.
Also, after I finished I realized I used a really thick (and heavy) wood: MDF 7mm for the side and 5mm for the top and bottom cover, if I just use more light wood it would be fine and it would be lighter and easier to carry it.
So start measuring your guitar:
With the basic measurements:
1. Build the the two sides of the box.
I did the bottom one, a bit higher than the top cover, so the guitar can fit perfect and it can close with out any problems.
I basically glue the wood and then used nails/screws to make it resistant.
-Top cover, do it as the same but with a bit less height.
2. Guitar shape
With the foam place your guitar on hit, and draw the shape of it. I used high density foam, simple beacuse I had it and it breaks less than the regular. To cut it, you can use a small saw, a cutter, I used an old guitar string attached to a power source until it got red hot so I can do clean cuts.
You end up with something like this:
I did mine, a bit bigger than the guitar I can wrap it with a soft cloth late. Take that into account.
This is how it fits, please do the square part to fit the size of your box.
3. Stands for the neck
With more wood I did two stands to fit the neck on it. Please measure measure and double measure everything-take the size of the neck for the stands, and measure how high your guitar will end up.
4. Set all the parts, and check how the guitar fits.
With a drilling tool, I added the hinges and the top cover:
I also did a cover on the bottom side, with Ethylene-vinyl acetate rubber. So the guitar doesnt sit on plain wood even though I used a cloth.
I was (am) a tottal noob when it comes to do this kinds upholstery. I use black synthetic leather.
I started with both sides of the case separately. I did the leather first and the soft fabrics later.
I used a contact glue and a stapler to get the fabric.
I had problem with poor measurement and low experience with upholstery. Be sure to use a glue that is compatible with foam, otherwise it will melt it and all your effort will be wasted.
Also look out and for tricky parts, I´d rather use small parts of cloth later.
6. Finishing touches
At this point guitar fits perfect, all the upholstery is done.
At this point I installed the hinges, the closing hooks.
Optional but useful: Add a handle to carry it around and wire/small chains to secure the top part dont fall when you open it.