Walker Presentation Case

[bushmaster65]

OK jlb43...here goes

I made the box completely out of scraps of red oak and oak plywood.
Once I got the stitches out and bought a new band saw, I used some old 2x4 scraps and cut strips that actually fit about 1/16" below the edge. Damn convenient if ya ask me! I used the two pics below for layout ideas:

I liked the curved divider in the first but went with 2nd for ease of angles.
I glued the HELL out of those dividers with my strongest bottle of tightbond
and figured the material would add some strength and rigidity as well.

I tried scissors and was so frustrated that after getting off the phone
with the emergency stress councilor, went to wally world and found this rotary
cutter. best invention in the world for fabric cutting.

Next, I used a tailors tape and measured the whole length and width and added about 1/4". In the picture below, I glued one side then the other right after. As I came to an intersection, I simply layed it on top of the offending border strip and split the fabric with an xacto knife.

The glue I used was E600 found at hobby lobby and wally world. I used two sets of extra divider strips . One set for spreading the glue and one set for tucking and tamping down the material. Beveled the glue spreader to get right into the joints and layed it on moderately thick. This stuff stays thick enough to hold but soft enough to allow you to slide the material into the joints. If you come up just a bit short when it meets the floor don't worry because the thickness of the material will tuck into that gap when you lay the floor piece.

 

[bushmaster65]

continued...

*note* Placing the material onto the border areas of the lid and box is a pain in the a**!
cut an extra 1/4" in width.
First glue the material face down on the upper edge. Make sure its stuck all along the edge. Then fold it over and apply to the "wall". sliding it down into the joint area until the top is flush with the wood.
Don't worry about any glue on the material, it reaches a consistency of rubber cement and can be plucked right off. UNLESS its saturated, then just decide if you have to redo. It dries clear enough to be inconspicuous.
Next, I used a cheap Photo paper cutter and cut blocks of paper
and placed them into the floor area. Taping them together as I went until I had a solid pattern.

next, I transfered this to a poster board and wrapped/glued the material to one side and finished the lid off.
applied the same principle to the pattern for the pistol slot:

A bit of a setback occured (not at all related to the half consumed crown and coke on the bench next to me) when I went to fit this into the box:

...and realized I covered the wrong side!!!!!!
The one resounding obscenity was loud enough to bring my wife to the garage to make sure I didn't need more stitches
Anyway, I said to hell with it and laid the rough patterns on the material
and used the rotary cutter by hand and it worked out surprisingly well. I would do it this way in fact if you have enough material to cover goofs here and there.
So that sums up the material process. any questions or suggestions welcomed.
In fact, lets see those boxes. Store bought or home made. Even the tupperware coffins

 

[jlb43]

Thanks bushmaster. I will get one of those rotary cutters for sure.