Here is a 3u flight case I designed and built for my Sennheiser wireless system. The case will house four wireless receivers and two in ear monitor transmitters. The six body packs will be stowed in a compartment built into one of the lids..
![](http://www.paulwalster.com/tp-images/1uidIMG_2842.JPG)
![](http://www.paulwalster.com/tp-images/1uidIMG_2820.jpg)
The aluminium extrusions.. Note the Fender Telecaster (top left) for scale..
![](http://www.paulwalster.com/tp-images/1uidIMG_2818.jpg)
The extrusions had to be cut to within a millimetre. No easy task with angled aluminium..
![](http://www.paulwalster.com/tp-images/1uidIMG_2821.jpg)
I used abs corners to simplify the construction..
![](http://www.paulwalster.com/tp-images/1uidIMG_2823.JPG)
![](http://www.paulwalster.com/tp-images/1uidIMG_2825.jpg)
Cutting the panels from Phenol coated 6.5mm birch ply (Hexaboard)
![](http://www.paulwalster.com/tp-images/1uidIMG_2824.JPG)
![](http://www.paulwalster.com/tp-images/1uidIMG_2828.JPG)
![](http://www.paulwalster.com/tp-images/1uidIMG_2831.JPG)
![](http://www.paulwalster.com/tp-images/1uidIMG_2838.JPG)
Building the covers..
![](http://www.paulwalster.com/tp-images/1uidIMG_2836.JPG)
![](http://www.paulwalster.com/tp-images/1uidIMG_2836.JPG)
I used a hacksaw and rotary tool for the cut outs.. Not the easiest of jobs!
![](http://www.paulwalster.com/tp-images/1uidIMG_2841.jpg)
Catches held in place with (Tony Kennah's!) clamps whilst riveting down.
![](http://www.paulwalster.com/tp-images/1uidIMG_2844.jpg)
And it makes a great rocking horse for my daughter Fern!