How To Build Flight Case and Transport Box

[Mads Barnkob]

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$, they are meant for transportation of my large Tesla coil with 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.

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My first draft drawings on the sizes of the boxes


Later I put it all in a spreadsheet (attached at the bottom) to get a precise calculation on the weight of the boxes when trying out different layouts or panel thickness. As it can be seen from the calculations, it is the panels that make up almost all of the weight, there is certainly not much to gain by skipping on the aluminum rails, hinges, handles or locks.

I bought handles, locks and rails from Adam Hall in Germany


The laminated plywood panels is cheapest to find at your local hardware store


Some details of the riveting and me next to the topload flight case for size reference, its huge!



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