10 Simple Steps: How to Build Internal Framing for Road Cases * bigfinish.com

Embark on a meticulous journey into the craftsmanship of road cases, the stalwart protectors of your precious equipment. Constructing the internal framework is a pivotal step, ensuring the structural integrity and longevity of these essential travel companions. This article will guide you through the intricacies of this crucial process, providing a comprehensive roadmap to constructing a robust and reliable internal framing system.

The art of road case construction lies in striking a delicate balance between strength, durability, and weight. With careful planning and meticulous execution, you can create a framework that meets the unique requirements of your equipment, whether it be a delicate musical instrument, a high-end camera rig, or a specialized scientific apparatus. Selecting the appropriate materials and employing sound engineering principles are paramount to ensuring the longevity and functionality of your road case.

Sturdy plywood, renowned for its strength-to-weight ratio, serves as the foundation for the framework. Precisely cut and strategically positioned, these plywood panels create a rigid structure that effectively disperses impact forces. Additionally, metal braces and reinforcements, meticulously welded or bolted into place, provide enhanced support and rigidity, ensuring that your equipment remains secure and protected against even the most rigorous transportation conditions. The choice of hardware, including high-quality hinges, latches, and handles, plays a crucial role in ensuring the seamless operation and durability of your road case.

Selecting the Appropriate Materials

Choosing the appropriate materials for your internal framing is essential for ensuring the durability and longevity of your road cases. The type of material you select will depend on the specific requirements of your application. Here are the key considerations when selecting materials:

Weight and Density

The weight of the framing materials will impact the overall weight of the case. Lightweight materials like aluminum or ABS plastic can be suitable for smaller cases, while heavier materials like plywood or steel may be necessary for larger and heavier items. Density is also important, as higher-density materials provide greater strength and durability.

Strength and Durability

The framing materials must be able to withstand the rigors of transport. Plywood, for example, is known for its strength and impact resistance, making it a popular choice for road cases. Steel is even stronger, but it is also heavier and more expensive. Aluminum and ABS plastic offer a balance between strength and weight, making them suitable for many applications.

Ease of Working

The material you choose should be easy to work with, especially if you plan to build your own cases. Plywood and aluminum are relatively easy to cut and shape, while steel requires specialized tools and techniques.

Cost

The cost of the framing materials will also be a factor to consider. Plywood is typically the most affordable option, while steel is the most expensive. Aluminum and ABS plastic fall somewhere in between.

Material	Weight	Strength	Ease of Working	Cost
Plywood	Medium	High	Easy	Low
Steel	High	Very High	Difficult	High
Aluminum	Light	High	Medium	Medium
ABS Plastic	Light	Medium	Easy	Low

Determining the Dimensions for the Case

The dimensions of the case will depend on the size and shape of the equipment you are transporting. It is important to measure the equipment carefully and allow for some extra space around it. This will help to protect the equipment from damage during transport.

Here are some tips for determining the dimensions of the case:

Measure the length, width, and height of the equipment.
Add 2-4 inches to each dimension to allow for some extra space around the equipment.
Make sure that the dimensions of the case are compatible with the size of your vehicle.

Once you have determined the dimensions of the case, you can start building the internal framing.

Calculating the Size of the Internal Framing

The internal framing of the case should be slightly smaller than the internal dimensions of the case. This will allow for the equipment to fit snugly inside the case and prevent it from moving around during transport.

To calculate the size of the internal framing, subtract 1 inch from each dimension of the internal dimensions of the case.

For example, if the internal dimensions of the case are 24″ x 18″ x 12″, the internal framing should be 23″ x 17″ x 11″.

The following table shows the recommended dimensions for the internal framing of a road case:

Internal Dimensions of Case	Dimensions of Internal Framing
24″ x 18″ x 12″	23″ x 17″ x 11″
30″ x 24″ x 15″	29″ x 23″ x 14″
36″ x 28″ x 18″	35″ x 27″ x 17″

Assembling the Frame Sides

Cut two pieces of plywood to the desired height and width of the frame sides. Align the edges of the plywood pieces and clamp them together. Apply wood glue to the edges and secure them with screws every 4 inches along the length of the sides. Repeat this process to assemble the other frame side.

Once the frame sides are assembled, attach the top and bottom pieces of plywood. Cut the top and bottom pieces to the desired length and width, ensuring they are perpendicular to the frame sides. Apply wood glue to the edges of the top and bottom pieces and secure them with screws every 4 inches along the length of the sides.

Next, reinforce the corners of the frame by adding corner braces. Cut four pieces of plywood or metal to form triangles that fit into the corners of the frame. Apply wood glue or use screws to secure the corner braces in place. This will provide additional strength and stability to the frame.

Installing the Panels

Cut two pieces of plywood to the desired height and width of the panels. Align the edges of the plywood pieces and clamp them together. Apply wood glue to the edges and secure them with screws every 4 inches along the length of the sides. Repeat this process to assemble the other panel.

Once the panels are assembled, attach them to the frame by placing them inside the frame and securing them with screws every 4 inches along the length of the sides. Ensure that the panels are flush with the edges of the frame.

To provide additional strength, add cross braces to the panels. Cut several pieces of plywood or metal to the desired length and attach them diagonally across the panels. Secure the cross braces with screws every 4 inches along their length.

Adding Reinforcement and Accessories

To further reinforce the road case, add metal or plywood gussets to the corners of the frame. Gussets are triangular pieces that fit into the corners and provide additional support. Secure the gussets with screws or bolts.

Additionally, you can add accessories such as handles, latches, and hinges. Handles allow for easy carrying, while latches and hinges ensure the road case remains securely closed during transport.

Accessory	Function
Handles	For carrying the road case
Latches	For securing the lid of the road case
Hinges	For attaching the lid to the base of the road case
Gussets	For reinforcing the corners of the road case

Trimming the Frame Components

Cutting the Dividing Ribs

Measure and mark the dividing ribs at their appropriate lengths. Use a circular saw or miter saw to cut the ribs to size. Ensure precise cuts for a snug fit.

Trimming the Side Panels

Align the side panel with the dividing ribs and mark the points where the ribs intersect. Use a circular saw or jigsaw to cut the side panels to the desired length and shape, following the marked lines.

Rounding the Corners

To prevent sharp edges, use a router or sanding block to round the corners of the side panels and dividing ribs. The radius of the corners should match the thickness of the panels and ribs to provide a smooth transition.

Mitering the Corners

For a professional-looking finish, it’s recommended to miter the corners of the side panels and dividing ribs. Use a miter saw to cut 45-degree angles at the ends of the panels and ribs. Ensure precise cuts for a seamless fit when assembling the frame.

Tool	Purpose
Circular saw	Cutting side panels and dividing ribs to length
Miter saw	Mitering corners and cutting dividing ribs to length
Router or sanding block	Rounding corners for a smooth transition

Assembling the Frame Sides and Panels

Step 1: Assemble the Corners

Apply wood glue to the corner joints and insert the corner brackets into place. Secure the brackets with screws. Ensure the corners are square and the brackets are flush with the wood.

Step 2: Join the Frame Sides

Place the two frame sides parallel to each other on a flat surface. Apply wood glue to the edges and connect the sides using the aluminum angle extrusions. Secure with screws.

Step 3: Construct the Frame Bottom

Position the bottom panel inside the frame sides and apply wood glue. Secure the panel with screws through the angle extrusions. Ensure the bottom panel is flush with the frame sides.

Step 4: Connect the Side Panels

Place the side panels inside the frame and align them flush with the edges. Apply wood glue and secure the panels with screws through the angle extrusions. The side panels should be flush with the top of the frame.

Step 5: Reinforce the Frame (Optional)

For added strength, you can install additional reinforcement inside the frame. This can include cross-bracing, struts, or angle irons. Reinforcements can be screwed or bolted into the wood and/or aluminum extrusions. For example:

Reinforcement Type	Placement	Purpose
Cross-bracing	Diagonal inside the frame	Reduces twisting
Struts	Vertical or horizontal inside the frame	Supports heavy loads
Angle irons	Along the corners or edges	Strengthens the seams

Installing Braces and Reinforcements

Plywood Gussets

Plywood gussets provide additional strength to the corners of the frame. Cut a triangular piece of plywood to fit snugly into the corner and secure it with screws or nails.

Metal Angle Brackets

Metal angle brackets offer a stronger alternative to plywood gussets. Position the brackets at the corners and secure them with bolts or screws.

Reinforcing Crossbars

Reinforcing crossbars add support to the middle of the frame. Cut a crossbar to the length of the frame and attach it using screws or nails.

Corner Plates

Corner plates provide extra support to the joints between the sides and ends of the frame. Secure the plates with screws or rivets.

U-Shaped Brackets

U-shaped brackets can be used to reinforce the corners of the frame and provide a mounting point for handles or other accessories. Bolt or screw the brackets into place.

Table of Reinforcement Options

Adding Hinges and Latches

Hinges

Hinges are crucial for providing access to the interior of the road case. Choose hinges that are durable, rust-resistant, and appropriate for the weight and size of the case. To install hinges:

Mark the hinge locations on the lid and case body.
Use a drill press to create countersunk holes for the hinge screws.
Place the hinges in the holes and secure them with screws.

Latches

Latches secure the lid of the road case in place during transport. Look for latches that are sturdy, easy to operate, and designed to withstand the rigors of travel. To install latches:

Mark the latching positions on the lid and case body.
Drill pilot holes for the latch screws.
Install the latches and secure them with screws.

Latch Type	Description
Butterfly Latch	Large, heavy-duty latch with two interlocking wings for secure closure.
Cam Latch	Spring-loaded latch that engages with a hook or receiver for quick and easy opening and closing.
T-Handle Latch	Latch with a T-shaped handle that provides a secure grip and easy release.

When choosing hinges and latches, consider the following factors:

Load capacity: Ensure the hinges and latches can support the weight of the case and its contents.
Durability: Opt for components made from durable materials that can withstand wear and tear.
Ease of use: Select hinges and latches that are easy to operate, even when wearing gloves or in low-light conditions.
Compatibility: Make sure the hinges and latches are compatible with the type of road case you are building.

Finishing

Once the internal framing is complete, it’s time to finish the interior of the case. This can be done with a variety of materials, including fabric, carpet, plastic, or foam. The choice of material will depend on the intended use of the case and the desired level of protection.

If you’re using fabric or carpet, staple or glue it to the inside of the case. For plastic or foam, you can use adhesive or screws to secure it in place.

Be sure to finish all edges of the case, including the corners. This will help to protect the interior of the case from damage and prevent the contents from shifting around.

Edge Protection

The edges of the case are especially vulnerable to damage, so it’s important to protect them. This can be done with a variety of materials, including metal, plastic, or wood.

Metal edge protectors are the most durable option, but they can also be expensive. Plastic edge protectors are a less expensive option, but they are not as durable as metal. Wood edge protectors are a good compromise between durability and cost.

To install edge protectors, simply attach them to the edges of the case with screws or glue. Be sure to space the edge protectors evenly around the case for maximum protection.

Types of Edge Protectors

Type	Material	Durability	Cost
Metal	Steel or aluminum	Excellent	$$$
Plastic	Polypropylene or polyethylene	Good	$$
Wood	Hardwood or plywood	Fair	$

Installing Caster Sockets

Caster sockets provide a secure mounting point for the casters, ensuring smooth and reliable transportation. To install them, follow these steps:

Mark the desired caster locations on the base and plywood.
Use a hole saw to create holes for the sockets.
Align the sockets with the holes and insert them.
Secure the sockets with screws or bolts.

Foam Lining

Foam lining provides protection and cushioning to the contents of the road case. Here’s how to install it:

Measure and cut the foam to fit the interior of the case.
Apply spray adhesive to the foam and the case lining.
Firmly press the foam into place, making sure there are no gaps or wrinkles.

Customized Foam Cutouts

For additional protection and organization, consider creating customized foam cutouts that fit the exact dimensions of your equipment. This can be done using a foam cutter or by ordering custom-cut foam from a supplier.

Foam Density and Thickness

Select foam with the appropriate density and thickness for your specific needs. Higher density foam provides more protection, while thicker foam provides better cushioning. Consider the weight and sensitivity of your equipment when making your choices.

Foam Specifications
Foam Density	Recommended for
1.5-2.0 lb/ft³	Light-duty applications, such as carrying cases for electronics
2.5-3.0 lb/ft³	Medium-duty applications, such as road cases for musical instruments
3.5-4.0 lb/ft³	Heavy-duty applications, such as road cases for photography equipment

Testing and Inspecting the Internal Framing

After assembling the internal framing, it’s crucial to thoroughly test and inspect it to ensure it meets the intended requirements. Here are some key steps to follow:

1. Load Testing: Apply a representative load to the framed area to simulate real-world conditions. Ensure that the framing can withstand the load without excessive deflection or damage.

2. Impact Testing: Simulate potential impacts by dropping a weight onto the framing. Check for any damage, especially at joints and critical support points.

3. Fatigue Testing: Subject the framing to repeated loading and unloading cycles to assess its durability and fatigue resistance.

4. Joint Integrity: Carefully examine all joints to ensure they are properly secured and can withstand the anticipated forces.

5. Hardware Inspection: Check all screws, bolts, and other hardware for tightness and proper installation.

6. Material Inspection: Visually inspect all materials used for framing and supporting structures for any defects or imperfections.

7. Measuring and Alignment: Use measuring tools to verify that the framing is square and aligned, ensuring proper fit within the road case.

8. Clearance Checks: Assess the clearance between the framed area and any internal components to ensure there is sufficient space for movement and operation.

9. Electrical Continuity: If the framing includes electrical components, such as cable channels or mounting brackets, test for proper electrical continuity and grounding.

10. Documentation and Reporting: Record the results of all tests and inspections in a detailed report, including any observations or potential areas for improvement. This documentation will serve as a valuable reference for future maintenance and troubleshooting.

How To Build Internal Framing For Road Cases

Building internal framing for road cases is a great way to protect your valuable gear while on the road. A well-built internal framing can help to prevent your gear from getting damaged in the event of a fall or collision, and it can also make it easier to transport your gear from one place to another.

To build internal framing for a road case, you will need the following materials:

Plywood
2x4s
Screws
Nails

Once you have gathered your materials, you can follow these steps to build the internal framing for your road case:

Start by cutting the plywood to the desired size for the inside of your road case.
Next, cut the 2x4s to the desired length for the framing.
Screw the 2x4s to the plywood, spacing them evenly apart.
Once the framing is complete, you can add nails to the corners for added strength.
Finally, you can add a layer of padding to the inside of the road case to protect your gear.

Building internal framing for road cases is a relatively simple process that can be completed in a few hours. However, it is important to take your time and make sure that the framing is sturdy enough to protect your gear. By following these steps, you can build a road case that will last for years to come.