How To Build Flight Case and Transport Box

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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.ph...
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19 янв 2021

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Комментарии : 52

@KaizerPowerElectronicsDk 3 года назад

The pointer for the total price in the spreadsheet is at a wrong place :( The total is around ~500$ for the 3 boxes.

@jobaecker9752 Год назад

Sehr schön und auch sehr günstig!

@zaprodk 3 года назад

Very nice - now i want to make some custom boxes as well :)

@KaizerPowerElectronicsDk 3 года назад

Ask me anything if you got questions about it :)

@JimStamm-id6wv 8 месяцев назад

Great Job!!

@KaizerPowerElectronicsDk 8 месяцев назад

Thank you Jim. They are still in use :)

@Handskemager 2 года назад

God video! Godt lavet :)

@miguelzamora2011 2 года назад

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!

@KaizerPowerElectronicsDk 2 года назад

What materials exactly? I am pretty sure I mention it all in the video.

@miguelzamora2011 2 года назад

@@KaizerPowerElectronicsDk oh my mistake, I missed the named of the walls your using. I'll go back to refer the video👍🏾

@KaizerPowerElectronicsDk 2 года назад

@@miguelzamora2011 I am not sure of the name, its the cheap laminated wood used for concrete pouring.

@bakoguy5330 8 месяцев назад

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

@DearTony1005 Месяц назад

Glad you said no homo, I was just thinking you were gay.

@henriklehmannthomsen9865 3 года назад

'Wow look at that baby'....eyes shining 9:44 Timestamp in the video. I Think we see true love :)

@KaizerPowerElectronicsDk 3 года назад

Wet eyes and everything :)

@vaclavwaloschek743 3 года назад

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.

@KaizerPowerElectronicsDk 3 года назад

The two large boxes was properly over something like 6-8 evenings of 3-6 hours

@officialpoa3171 Месяц назад

*My son, you all REALLY, should have built shock absorber cases instead, for gear like that!*

@LesWheelerBass 3 года назад

What type of rivets and size are you using? Good work mate.

@KaizerPowerElectronicsDk 3 года назад

I used 4.0x11.4mm, you could properly use shorter ones. Type 12-971 here www.biltema.dk/varktoj/handvarktoj/nittevarktoj/nitter/nitte-2000016806

@massimofabbri1175 9 месяцев назад

Nice video! I wanted only ask you if Is better your solution to built the structure or is better to use casemaker profiles.. Thanks

@KaizerPowerElectronicsDk 9 месяцев назад

I had to do it my way, because casemaker profiles only comes in 1 meter length. There was very little hardware to be found, premade for 2 meter long cases. Casemaker profiles seems to be double the price, so its a trade-off between your time and money. But I would properly buy casemaker profiles for cases that are less than 1 meter :)

@massimofabbri1175 9 месяцев назад

@@KaizerPowerElectronicsDk Thanks you very much! But I think your structure is more solid than the other one with casemaker profiles

@KaizerPowerElectronicsDk 9 месяцев назад

@@massimofabbri1175 True, but it comes with a price in additional weight :) They are heavy.

@joshuakelley383 3 года назад

where did you source all of your hardware for these cases im interested in building some for my personal lighting equipment

@KaizerPowerElectronicsDk 3 года назад

You can usually find it at any event/lightning company, like "Adam Hall" in Gernany. All wood is from local hardware store.

@lit2021 3 года назад

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.

@KaizerPowerElectronicsDk 3 года назад

Current building material prices in 2021/corona times could properly have shifted the price differences....

@shawncarson5930 2 года назад

Having a hard time finding that thin laminated ply board in the US. Any suggestions?

@KaizerPowerElectronicsDk 2 года назад

Did you try looking for wood used in concrete pouring form building? A more expensive version is used for construction of trailers, but also better quality.

@SeanBZA 3 года назад

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.

@KaizerPowerElectronicsDk 3 года назад

Which thickness panels do you use? I would love to have used 12 or 15 mm for sturdiness, but the weight of the added thickness was a big no. All the aluminum rails does all the rigidity, but I can foresee that some years of use and replacement of rivets to bolt+washer+nut might be necessary if the rivets are stressed enough to break the wood.

@SeanBZA 3 года назад

@@KaizerPowerElectronicsDk Cheapest panels by me are 18mm, so used those. Yes thinner panels are better, but using an even glue bond will mean no rivets needed. Just some stretchy tape to hold the panels and edges together for the cure time of the urethane, which will probably mean a day of tape. I used the shutterply to make simple shelving, and did the dimensions to use the full sheet with only a single cut width. Thus the edge screws, to get a strong joint.

@KaizerPowerElectronicsDk 3 года назад

@@SeanBZA woah yeah 18 mm is never going to happen with big boxes like this! That would be 80 kg just for the big box! You are not using rivets on the aluminum rails?

@SeanBZA 3 года назад

@@KaizerPowerElectronicsDk 18mm does not need rails, the join itself is strong enough, though a few corners had braces put in.

@KaizerPowerElectronicsDk 3 года назад

@@SeanBZA Now I understand :)

@luigie2555 2 года назад

Hey, where's Super Mario? 😄 🤣

@djdouglas2705 3 года назад

How much do you charge me for making me one flight case for 2 55 inch tv

@nabzim 3 года назад

Are you serious???

@omarguerrero6417 11 месяцев назад

No one Me:what a flight case

@KaizerPowerElectronicsDk 11 месяцев назад

When a flight case doubles as a coffin :)

@memes_haram 3 года назад

Peter Baelish looks different here

@KaizerPowerElectronicsDk 3 года назад

But then who was TV?

@memes_haram 3 года назад

@@KaizerPowerElectronicsDk I thought it was you

@ranitguha7935 3 года назад

Are you a german?

@KaizerPowerElectronicsDk 3 года назад

A bit further north, Denmark.

@ranitguha7935 3 года назад

@@KaizerPowerElectronicsDk german speaking denmark?

@KaizerPowerElectronicsDk 3 года назад

@@ranitguha7935 Danish, but all learn German in school :)

@ranitguha7935 3 года назад

@@KaizerPowerElectronicsDk I asked you because I thought kaiser wilhelm

@KaizerPowerElectronicsDk 3 года назад

@@ranitguha7935 It actually is inspired from a Norwegian band called Kaizers Orchestra :)

@ephemere82 2 года назад

too small case for the weight imho

@KaizerPowerElectronicsDk 2 года назад

There was no static load calculations done before hand. Just based on cheapest and easiest to get, so yes, they became heavier than they could have been.