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		<title>Marshall Amp Forum - The Backstage</title>
		<link>http://www.marshallforum.com/</link>
		<description>General discussions not covered by other forums.</description>
		<language>en</language>
		<lastBuildDate>Sat, 21 Nov 2009 01:47:06 GMT</lastBuildDate>
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			<title>Marshall Amp Forum - The Backstage</title>
			<link>http://www.marshallforum.com/</link>
		</image>
		<item>
			<title>Curious</title>
			<link>http://www.marshallforum.com/backstage/9612-curious.html</link>
			<pubDate>Fri, 20 Nov 2009 20:26:38 GMT</pubDate>
			<description>how old are the people on this forum?</description>
			<content:encoded><![CDATA[<div>how old are the people on this forum?</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>Starchild132</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9612-curious.html</guid>
		</item>
		<item>
			<title>New Group</title>
			<link>http://www.marshallforum.com/backstage/9603-new-group.html</link>
			<pubDate>Fri, 20 Nov 2009 16:53:18 GMT</pubDate>
			<description><![CDATA[I just wanted everbody to know, i've started a group called "The Next Shredders" if you guys consider yourselves this as well feel free to join i'm trying this group HUGE  :cheers:]]></description>
			<content:encoded><![CDATA[<div>I just wanted everbody to know, i've started a group called &quot;The Next Shredders&quot; if you guys consider yourselves this as well feel free to join i'm trying this group HUGE  :cheers:</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>Starchild132</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9603-new-group.html</guid>
		</item>
		<item>
			<title>Trouble in a band</title>
			<link>http://www.marshallforum.com/backstage/9581-trouble-band.html</link>
			<pubDate>Thu, 19 Nov 2009 19:40:31 GMT</pubDate>
			<description><![CDATA[I LIve in the Illinois area (close to Alton) and i was wondering if there any fellow musicians in the area preferably a rhythm guitarist/vocalist or a drummer that would want to get into a band?, i'm mainly into metal like Pantera, Megadeth, Children of Bodom, Nevermore, etc, and my band name is Psychopathy but its so hard to find anybody in the area if anybody can help please let me know, alos a sidenote my age restrictions are not over 21 and not under 16 thanks]]></description>
			<content:encoded><![CDATA[<div>I LIve in the Illinois area (close to Alton) and i was wondering if there any fellow musicians in the area preferably a rhythm guitarist/vocalist or a drummer that would want to get into a band?, i'm mainly into metal like Pantera, Megadeth, Children of Bodom, Nevermore, etc, and my band name is Psychopathy but its so hard to find anybody in the area if anybody can help please let me know, alos a sidenote my age restrictions are not over 21 and not under 16 thanks</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>Starchild132</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9581-trouble-band.html</guid>
		</item>
		<item>
			<title>Fav song intros</title>
			<link>http://www.marshallforum.com/backstage/9575-fav-song-intros.html</link>
			<pubDate>Thu, 19 Nov 2009 10:46:51 GMT</pubDate>
			<description><![CDATA[I don't know if I'm the only one, but I really like song intros (well some of them) and I have actually been known in the past to stop the song and move on to another song once the intro has finished.

Here's some of my favourites

YouTube - The Sex Pistols - Pretty Vacant - Live On The Late Late Show
YouTube - ONLY ONES - ANOTHER GIRL ANOTHER PLANET
Have you any intros you like to hear? I might just be me.]]></description>
			<content:encoded><![CDATA[<div>I don't know if I'm the only one, but I really like song intros (well some of them) and I have actually been known in the past to stop the song and move on to another song once the intro has finished.<br />
<br />
Here's some of my favourites<br />
<br />
<div style="display: none;" id="ame_noshow_other_1258768026_1">
        <a href="http://www.youtube.com/watch?v=hvxrYm4nxXY&amp;feature=related" title="YouTube - The Sex Pistols - Pretty Vacant - Live On The Late Late Show" target="_blank">YouTube - The Sex Pistols - Pretty Vacant - Live On The Late Late Show</a>
</div>
<div style="display: inline;" id="ame_doshow_other_1258768026_1">
<div align="center">
<table class="tborder" cellpadding="6" cellspacing="1" width="425" style="margin:10px 0">
<thead>
        <tr>
                <td class="tcat" colspan="2" style="text-align:center">
                        <a href="http://www.youtube.com/watch?v=hvxrYm4nxXY&amp;feature=related" title="YouTube - The Sex Pistols - Pretty Vacant - Live On The Late Late Show" target="_blank">YouTube - The Sex Pistols - Pretty Vacant - Live On The Late Late Show</a>
                </td>
        </tr>
</thead>
<tbody>
        <tr>
                <td class="panelsurround" align="center">
<object width="425" height="350">
<param name=''movie'' value="http://www.youtube.com/v/hvxrYm4nxXY&amp;ap=%2526fmt%3D18&amp;fs=1"></param>
<param name="allowFullScreen" value="true"></param>
<embed src="http://www.youtube.com/v/hvxrYm4nxXY&amp;ap=%2526fmt%3D18&amp;fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="350" wmode="transparent"></embed></object>
</td>
        </tr>
</tbody>
</table></div>
</div><br />
<div style="display: none;" id="ame_noshow_other_1258768026_2">
        <a href="http://www.youtube.com/watch?v=VvO7HNQPFRI" title="YouTube - ONLY ONES - ANOTHER GIRL ANOTHER PLANET" target="_blank">YouTube - ONLY ONES - ANOTHER GIRL ANOTHER PLANET</a>
</div>
<div style="display: inline;" id="ame_doshow_other_1258768026_2">
<div align="center">
<table class="tborder" cellpadding="6" cellspacing="1" width="425" style="margin:10px 0">
<thead>
        <tr>
                <td class="tcat" colspan="2" style="text-align:center">
                        <a href="http://www.youtube.com/watch?v=VvO7HNQPFRI" title="YouTube - ONLY ONES - ANOTHER GIRL ANOTHER PLANET" target="_blank">YouTube - ONLY ONES - ANOTHER GIRL ANOTHER PLANET</a>
                </td>
        </tr>
</thead>
<tbody>
        <tr>
                <td class="panelsurround" align="center">
<object width="425" height="350">
<param name=''movie'' value="http://www.youtube.com/v/VvO7HNQPFRI&amp;ap=%2526fmt%3D18&amp;fs=1"></param>
<param name="allowFullScreen" value="true"></param>
<embed src="http://www.youtube.com/v/VvO7HNQPFRI&amp;ap=%2526fmt%3D18&amp;fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="350" wmode="transparent"></embed></object>
</td>
        </tr>
</tbody>
</table></div>
</div><br />
Have you any intros you like to hear? I might just be me.</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>theflyingmat</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9575-fav-song-intros.html</guid>
		</item>
		<item>
			<title>The Best Patriotic Speech Ever Given!!!</title>
			<link>http://www.marshallforum.com/backstage/9520-best-patriotic-speech-ever-given.html</link>
			<pubDate>Wed, 18 Nov 2009 00:42:13 GMT</pubDate>
			<description><![CDATA[For all you prior military, you'll love this.  Everyone else too, probably.  Just watch.  :)


YouTube - Infantry BasicTraining Graduation Speech ?? ???? ?????]]></description>
			<content:encoded><![CDATA[<div>For all you prior military, you'll love this.  Everyone else too, probably.  Just watch.  :)<br />
<br />
<br />
<div style="display: none;" id="ame_noshow_other_1258768026_3">
        <a href="http://www.youtube.com/watch?v=uXJY_wJHwAY" title="YouTube - Infantry BasicTraining Graduation Speech ?? ???? ?????" target="_blank">YouTube - Infantry BasicTraining Graduation Speech ?? ???? ?????</a>
</div>
<div style="display: inline;" id="ame_doshow_other_1258768026_3">
<div align="center">
<table class="tborder" cellpadding="6" cellspacing="1" width="425" style="margin:10px 0">
<thead>
        <tr>
                <td class="tcat" colspan="2" style="text-align:center">
                        <a href="http://www.youtube.com/watch?v=uXJY_wJHwAY" title="YouTube - Infantry BasicTraining Graduation Speech ?? ???? ?????" target="_blank">YouTube - Infantry BasicTraining Graduation Speech ?? ???? ?????</a>
                </td>
        </tr>
</thead>
<tbody>
        <tr>
                <td class="panelsurround" align="center">
<object width="425" height="350">
<param name=''movie'' value="http://www.youtube.com/v/uXJY_wJHwAY&amp;ap=%2526fmt%3D18&amp;fs=1"></param>
<param name="allowFullScreen" value="true"></param>
<embed src="http://www.youtube.com/v/uXJY_wJHwAY&amp;ap=%2526fmt%3D18&amp;fs=1" type="application/x-shockwave-flash" allowfullscreen="true" width="425" height="350" wmode="transparent"></embed></object>
</td>
        </tr>
</tbody>
</table></div>
</div></div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>StootMonster</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9520-best-patriotic-speech-ever-given.html</guid>
		</item>
		<item>
			<title>KILL that fugging spamer!</title>
			<link>http://www.marshallforum.com/backstage/9458-kill-fugging-spamer.html</link>
			<pubDate>Sun, 15 Nov 2009 04:47:18 GMT</pubDate>
			<description>KILL that fugging spamer!

seriously, he filled all the forum sections with his jewelry rip off thing</description>
			<content:encoded><![CDATA[<div>KILL that fugging spamer!<br />
<br />
seriously, he filled all the forum sections with his jewelry rip off thing</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>carnada</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9458-kill-fugging-spamer.html</guid>
		</item>
		<item>
			<title><![CDATA[The "Whats your Job" Thread?]]></title>
			<link>http://www.marshallforum.com/backstage/9431-whats-your-job-thread.html</link>
			<pubDate>Sat, 14 Nov 2009 05:37:46 GMT</pubDate>
			<description>Men out there in the forum! whats your job? what do you do for a living, or what did you do for a living to get your amps!

dont be ashamed if your job isnt good! Every job has to be done by someone, and every job is an honest job! In fact, if you are one of those guys, im gonna start by sayin my job!

Im a DISHWASHER AT A RESTAURANT!:fingersx:




I gotta bad feelin bout this thrad</description>
			<content:encoded><![CDATA[<div>Men out there in the forum! whats your job? what do you do for a living, or what did you do for a living to get your amps!<br />
<br />
dont be ashamed if your job isnt good! Every job has to be done by someone, and every job is an honest job! In fact, if you are one of those guys, im gonna start by sayin my job!<br />
<br />
Im a DISHWASHER AT A RESTAURANT!:fingersx:<br />
<br />
<br />
<br />
<br />
<font size="1">I gotta bad feelin bout this thrad</font></div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>carnada</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9431-whats-your-job-thread.html</guid>
		</item>
		<item>
			<title>The DSL Conspiracy</title>
			<link>http://www.marshallforum.com/backstage/9395-dsl-conspiracy.html</link>
			<pubDate>Thu, 12 Nov 2009 00:29:54 GMT</pubDate>
			<description><![CDATA[Social group "The DSL Conspiracy" is now available to join.  Black helicopters are not required, however, membership is contingent upon owning any DSL model.  Thank you for your time.

Area 51 is a secret government tech research site.....Mafia had Kennedy dealt with.....Elvis is still alive.....]]></description>
			<content:encoded><![CDATA[<div>Social group &quot;The DSL Conspiracy&quot; is now available to join.  Black helicopters are not required, however, membership is contingent upon owning any DSL model.  Thank you for your time.<br />
<br />
<font size="1"><i>Area 51 is a secret government tech research site.....Mafia had Kennedy dealt with.....Elvis is still alive....</i>.</font></div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>thrawn86</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9395-dsl-conspiracy.html</guid>
		</item>
		<item>
			<title><![CDATA[You've lost that lovin' feeling]]></title>
			<link>http://www.marshallforum.com/backstage/9378-youve-lost-lovin-feeling.html</link>
			<pubDate>Wed, 11 Nov 2009 14:44:57 GMT</pubDate>
			<description><![CDATA[Hey, recently I seem to have lost all motivation to play, either with my band or just for the hell of it, I have missed gigs and rehearsals through just not wanting to play anymore, does anyone else feel the same way? or felt this way? how did you get past it and re-discover the 'lovin feeling?' even my recent purchase of an original '81 JCM 800 4010 combo has not enticed me into playing more, I used to practice about 6+ hours a day back when i was 15-19, now I have just turned 30 and it just feels dead.

I guess it started about 2 years ago, my band at the time was making somethig of it, record company interest (no really!) and a supporting gig with Bowling For Soup (yeah we played fun punk-pop) but then our drummer moved away, and we hired a new drummer, who was already playing with the other 4 guys as a covers band, and we seemed to just work on getting me into the covers and let the original side fall to the wayside, now 2 years later no-one wants to play the original stuff anymore and i really don't know why??? now we just play the usual pub-rock covers set down the 'Dog & Duck' archetypal pub, ok it maynever have worked out as it so often does but, at least we would have given it a shot?

OR am i just bitching about nothing?]]></description>
			<content:encoded><![CDATA[<div>Hey, recently I seem to have lost all motivation to play, either with my band or just for the hell of it, I have missed gigs and rehearsals through just not wanting to play anymore, does anyone else feel the same way? or felt this way? how did you get past it and re-discover the 'lovin feeling?' even my recent purchase of an original '81 JCM 800 4010 combo has not enticed me into playing more, I used to practice about 6+ hours a day back when i was 15-19, now I have just turned 30 and it just feels dead.<br />
<br />
I guess it started about 2 years ago, my band at the time was making somethig of it, record company interest (no really!) and a supporting gig with Bowling For Soup (yeah we played fun punk-pop) but then our drummer moved away, and we hired a new drummer, who was already playing with the other 4 guys as a covers band, and we seemed to just work on getting me into the covers and let the original side fall to the wayside, now 2 years later no-one wants to play the original stuff anymore and i really don't know why??? now we just play the usual pub-rock covers set down the 'Dog &amp; Duck' archetypal pub, ok it maynever have worked out as it so often does but, at least we would have given it a shot?<br />
<br />
OR am i just bitching about nothing?</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>Benito</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9378-youve-lost-lovin-feeling.html</guid>
		</item>
		<item>
			<title>Making a flightcase (Epi LTD Explorer bass) (long, big pics)</title>
			<link>http://www.marshallforum.com/backstage/9343-making-flightcase-epi-ltd-explorer-bass-long-big-pics.html</link>
			<pubDate>Tue, 10 Nov 2009 09:15:52 GMT</pubDate>
			<description><![CDATA[Hi.

I posted this originally on TalkBass, but as someone might have a desire to build a flightcase in here also, I decided to post it over here too.



Since there wasn’t an easily available case for the Epi LTD Explorer I recently bought, and a custom case is well beyond my budget, I decided to take the DIY route.

Usually DIY isn’t the best way to save money and that holds true in this case ;) also if the quite necessary tools aren’t available. The tools aren’t absolutely essential if You can get the panels and the extrusions pre-cut to correct lenghts.
Most sheet suppliers do offer cutting service and if accurate enough, that can save a lot of time and make moving the pieces a lot easier. Almost a 3 m^2 sheet may pose a bit of a transportation problem for some folks.

Having the extrusions cut properly is more important though, and that’s usually the reason people don’t build cases.



This is not intended to be a thorough tutorial to case-making, I’m just a hobbyist with the need and the necessary tools, not a professional. People with extensive experience in pro-casemaking will spot several “incorrect” methods I’m sure. There is however a reason for why I do things the way I do, and “that’s how I’ve always done it” is one of them. I do hope that this thread inspires some exchange of thought about the methods among the DIYers in TB.

I won’t go into areas of general woodworking or general metalworking either. You have to know how to make precice and repeatable cuts or the expensive materials will turn into a pile of scrap. (Or a smaller and smaller case up until it’s a perfect fit for a violin)



The extrusions and hardware I used is Adam Hall, but obviously any will do. I chose AH for convenience and previous experiences with that particular brand has been good.

I also used the cheapest 6.5mm waterproof plywood we have available in here, roughly translated as “farm-plywood”. The price reducing reason is that it’s not dead straight, but otherwise just as good as any other suitable variety. It’s only a problem when cutting, the smaller pieces are dead straight as the internal stresses diminish when reducing the size of the sheet.
The sheets we have in here are 1200mm*2400mm and it pretty much vanishes when making a big case like this one. You do have some leftovers, that’s true, and those can be used in another project, but usually not enough to make anything else than a mic-case or something like that.

There’s several ways to reduce the cost as well as improve the quality. I took the middle-way by using the materials easiest for me to get, while taking the advantage of the “modern” extrusions.
By “modern” I mean casemaker extrusions. Those weren’t available, at least not in here, in the stone ages (80’s) when I first started making some cases as a kid. Basemaker and Lidmaker extrusions weren’t available for me in adequate lenghts at the time of purchase, so I didn’t use those. Basemaker and Lidmaker extrusions take the miter saw requirements up a level or a two as well.



What obviously are the main points in a venture like this (for me anyway) are: the final price, how long it takes to make one and how much will it weigh.

The price ain’t bad IMHO. For about 110€ to the materials, You’ll get a professional looking case that will protect Your instrument well for a very long time.

Making an one off case like this, designing as You go is a slow process. I think I got this done with 10 hours on the box and additional 5 for the internal structure. The internal structure will take a lot of time or no time at all depending of the desired form, but I’d say that the box making time can be reduced in half for the additional cases.

The weight is directly proportional to how sturdy (cost efficient) You want the case to be. Using regular plywood of a reasonable stifness and protective properties will always be heavy, no way around that. The alternative materials however cost at least three times more, so plywood is the most used material.

The empty box tipped a household scale at 14.7 Kg, so that’s some indication of the weight.



Planning and designing the case, well anything really, is something that should be done with plenty of time. Quite important material savings can be acchieved if the planning is done properly. If You plan carefully, you don’t have to trim the edges of the corner protectors like I had to. Would’ve made the case even thicker though.





Where to start then?

The obvious determening factor is the instrument that the case is being made for.
Straight headstocks are easy depth-wise, but angled headstocks like in the Epi pose a bit of a problem. Even more so if the edge of the body is angled. A flat surface with some fillers should provide the needed mock up for the thickness measurement though. A cardboard template of the outline isn’t such a bad idea either when finding out the X-Y dimensions and the orientation of the instrument in the case.
I like to have at least the protective material thickness around the instrument, in this case 15mm, so that has to be added. On every surface.

If You’re tight on the external dimensions for some reason and/or you are shooting for a specific outside dimensions, the casemaker profile thickness has to be taken to account on the calculations. I didn’t care about that, I just determined the area that was needed and took the additional 5mm/side ID as a bonus. That’s usually a good thing as the measured dimensions tend to be in the “small side”.



Unlike a real cabinet maker, I like to build the box structure from bottom to the top to be completely ready, instead of the usual: ”make a closed box first and then cut it in half”.
While the “correct” method has its undisputed benefits, it does make fitting the edge extrusions a bit of a PITA. With an angle grinder and a steady hand it can be done though.

I also like to install the ball corners, corner protectors and misc. hardware afterwards.



A short pictorial of the project:



Here’s the materials for the box, save the rivets and a few other pieces of hardware:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3366.jpg 

A close up of the corner miters:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3360.jpg 

The mock-up installation with the ball corners.

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3368.jpg 


After the mock-up installation I found out that the lid locators were 5mm too long so a bit of trimming was in order.

A dry fit with the bass:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3369.jpg 

The base is glued:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3373.jpg 

Followed with the lid frame:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3374.jpg 

And the lid sheet with the profiles:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3375.jpg 

The small hardware is straight forward to install, but I had to do some trimming in order to the corner protectors and ball corners to fit properly.

As the devil is in the details, I installed a pair of regular framing angles to support the handle. (Changed the nuts for nylocs though)

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3381.jpg 

I also used stacking ball corners on the bottom of the case as the added friction surface makes the case more steady when transporting. I also plan to make at least one other case like this so stacking ability is a definite plus when storing and transporting.

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3387.jpg 





The interior design is something everyone has to figure out by themselves, to fit the materials they’re using. I happened to have a roll of frost insulation material, so that went into this case. It’s expensive as hell if You need to actually buy some, so a substitute may be a good idea ;). It's not particulary good looking either. 

Do keep in mind that all the synthetic (or natural for that matter) materials aren’t necessarily compatible with all the finishes. Avoid nasty surprises at all costs.


Anyway, here’s the thickness pieces to provide the angle for the body:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3388.jpg 

Followed by a few smooth and form fit layers:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3389.jpg 


And a couple of pics of a “finished” product:

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3394.jpg 

Image: http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3392.jpg 


“Finished” as there’s still some accessory compartments and such to be made.
Unfortunately I ran out of contact cement so those may have to wait.



Materials used in this particular project:

(Metric.)

6.5mm plywood:
2pcs 1345*450
2pcs 1345*70
2pcs 1345*50
2pcs 450*70
2pcs 450*50

Which roughly translates to 1.7 m^2


Adam Hall:

Extrusions (with miters):
7mm Casemaker 6106
4pcs 1347
4pcs 452
4pcs 54
4pcs 34

7mm hybrid lid 6102:
2pcs 1365
2pcs 610
4pcs 470
4pcs 209


Hardware:
2pcs 17295TP (locks)
4pcs  4124 (ball corner)
4pcs 4128 (stacking ball corner)
4pcs 4053 (corner reinforcment)
4pcs 4041 (corner reinforcment)
4pcs 4905TP (feet)
2pcs 2524 (strut hinge)
2pcs 2602 (hinge)
1pcs 3418 (handle)

~170 4,8mm POP-rivets
~20 5mm washers for reinforcment where the expanding end is on the plywood.

Hard cellfoam frost insulation material for the interior.

1L contact cement.

Construction glue, 2 tubes.


“Special” tools needed.

Power miter saw, non sliding preferable for sturdiness.
Power drill.
POP-riveter.
POP-rivet drill bit
(electric angle-grinder)
(center punch)


Regards
Sam]]></description>
			<content:encoded><![CDATA[<div>Hi.<br />
<br />
I posted this originally on TalkBass, but as someone might have a desire to build a flightcase in here also, I decided to post it over here too.<br />
<br />
<br />
<br />
Since there wasn’t an easily available case for the Epi LTD Explorer I recently bought, and a custom case is well beyond my budget, I decided to take the DIY route.<br />
<br />
Usually DIY isn’t the best way to save money and that holds true in this case ;) also if the quite necessary tools aren’t available. The tools aren’t absolutely essential if You can get the panels and the extrusions pre-cut to correct lenghts.<br />
Most sheet suppliers do offer cutting service and if accurate enough, that can save a lot of time and make moving the pieces a lot easier. Almost a 3 m^2 sheet may pose a bit of a transportation problem for some folks.<br />
<br />
Having the extrusions cut properly is more important though, and that’s usually the reason people don’t build cases.<br />
<br />
<br />
<br />
This is not intended to be a thorough tutorial to case-making, I’m just a hobbyist with the need and the necessary tools, not a professional. People with extensive experience in pro-casemaking will spot several “incorrect” methods I’m sure. There is however a reason for why I do things the way I do, and “that’s how I’ve always done it” is one of them. I do hope that this thread inspires some exchange of thought about the methods among the DIYers in TB.<br />
<br />
I won’t go into areas of general woodworking or general metalworking either. You have to know how to make precice and repeatable cuts or the expensive materials will turn into a pile of scrap. (Or a smaller and smaller case up until it’s a perfect fit for a violin)<br />
<br />
<br />
<br />
The extrusions and hardware I used is Adam Hall, but obviously any will do. I chose AH for convenience and previous experiences with that particular brand has been good.<br />
<br />
I also used the cheapest 6.5mm waterproof plywood we have available in here, roughly translated as “farm-plywood”. The price reducing reason is that it’s not dead straight, but otherwise just as good as any other suitable variety. It’s only a problem when cutting, the smaller pieces are dead straight as the internal stresses diminish when reducing the size of the sheet.<br />
The sheets we have in here are 1200mm*2400mm and it pretty much vanishes when making a big case like this one. You do have some leftovers, that’s true, and those can be used in another project, but usually not enough to make anything else than a mic-case or something like that.<br />
<br />
There’s several ways to reduce the cost as well as improve the quality. I took the middle-way by using the materials easiest for me to get, while taking the advantage of the “modern” extrusions.<br />
By “modern” I mean casemaker extrusions. Those weren’t available, at least not in here, in the stone ages (80’s) when I first started making some cases as a kid. Basemaker and Lidmaker extrusions weren’t available for me in adequate lenghts at the time of purchase, so I didn’t use those. Basemaker and Lidmaker extrusions take the miter saw requirements up a level or a two as well.<br />
<br />
<br />
<br />
What obviously are the main points in a venture like this (for me anyway) are: the final price, how long it takes to make one and how much will it weigh.<br />
<br />
The price ain’t bad IMHO. For about 110€ to the materials, You’ll get a professional looking case that will protect Your instrument well for a very long time.<br />
<br />
Making an one off case like this, designing as You go is a slow process. I think I got this done with 10 hours on the box and additional 5 for the internal structure. The internal structure will take a lot of time or no time at all depending of the desired form, but I’d say that the box making time can be reduced in half for the additional cases.<br />
<br />
The weight is directly proportional to how sturdy (cost efficient) You want the case to be. Using regular plywood of a reasonable stifness and protective properties will always be heavy, no way around that. The alternative materials however cost at least three times more, so plywood is the most used material.<br />
<br />
The empty box tipped a household scale at 14.7 Kg, so that’s some indication of the weight.<br />
<br />
<br />
<br />
Planning and designing the case, well anything really, is something that should be done with plenty of time. Quite important material savings can be acchieved if the planning is done properly. If You plan carefully, you don’t have to trim the edges of the corner protectors like I had to. Would’ve made the case even thicker though.<br />
<br />
<br />
<br />
<br />
<br />
Where to start then?<br />
<br />
The obvious determening factor is the instrument that the case is being made for.<br />
Straight headstocks are easy depth-wise, but angled headstocks like in the Epi pose a bit of a problem. Even more so if the edge of the body is angled. A flat surface with some fillers should provide the needed mock up for the thickness measurement though. A cardboard template of the outline isn’t such a bad idea either when finding out the X-Y dimensions and the orientation of the instrument in the case.<br />
I like to have at least the protective material thickness around the instrument, in this case 15mm, so that has to be added. On every surface.<br />
<br />
If You’re tight on the external dimensions for some reason and/or you are shooting for a specific outside dimensions, the casemaker profile thickness has to be taken to account on the calculations. I didn’t care about that, I just determined the area that was needed and took the additional 5mm/side ID as a bonus. That’s usually a good thing as the measured dimensions tend to be in the “small side”.<br />
<br />
<br />
<br />
Unlike a real cabinet maker, I like to build the box structure from bottom to the top to be completely ready, instead of the usual: ”make a closed box first and then cut it in half”.<br />
While the “correct” method has its undisputed benefits, it does make fitting the edge extrusions a bit of a PITA. With an angle grinder and a steady hand it can be done though.<br />
<br />
I also like to install the ball corners, corner protectors and misc. hardware afterwards.<br />
<br />
<br />
<br />
A short pictorial of the project:<br />
<br />
<br />
<br />
Here’s the materials for the box, save the rivets and a few other pieces of hardware:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3366.jpg" border="0" alt="" /><br />
<br />
A close up of the corner miters:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3360.jpg" border="0" alt="" /><br />
<br />
The mock-up installation with the ball corners.<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3368.jpg" border="0" alt="" /><br />
<br />
<br />
After the mock-up installation I found out that the lid locators were 5mm too long so a bit of trimming was in order.<br />
<br />
A dry fit with the bass:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3369.jpg" border="0" alt="" /><br />
<br />
The base is glued:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3373.jpg" border="0" alt="" /><br />
<br />
Followed with the lid frame:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3374.jpg" border="0" alt="" /><br />
<br />
And the lid sheet with the profiles:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3375.jpg" border="0" alt="" /><br />
<br />
The small hardware is straight forward to install, but I had to do some trimming in order to the corner protectors and ball corners to fit properly.<br />
<br />
As the devil is in the details, I installed a pair of regular framing angles to support the handle. (Changed the nuts for nylocs though)<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3381.jpg" border="0" alt="" /><br />
<br />
I also used stacking ball corners on the bottom of the case as the added friction surface makes the case more steady when transporting. I also plan to make at least one other case like this so stacking ability is a definite plus when storing and transporting.<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3387.jpg" border="0" alt="" /><br />
<br />
<br />
<br />
<br />
<br />
The interior design is something everyone has to figure out by themselves, to fit the materials they’re using. I happened to have a roll of frost insulation material, so that went into this case. It’s expensive as hell if You need to actually buy some, so a substitute may be a good idea ;). It's not particulary good looking either. <br />
<br />
Do keep in mind that all the synthetic (or natural for that matter) materials aren’t necessarily compatible with all the finishes. Avoid nasty surprises at all costs.<br />
<br />
<br />
Anyway, here’s the thickness pieces to provide the angle for the body:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3388.jpg" border="0" alt="" /><br />
<br />
Followed by a few smooth and form fit layers:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3389.jpg" border="0" alt="" /><br />
<br />
<br />
And a couple of pics of a “finished” product:<br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3394.jpg" border="0" alt="" /><br />
<br />
<img src="http://i209.photobucket.com/albums/bb229/Helko58/Bass/Cases/Explorer/DSCN3392.jpg" border="0" alt="" /><br />
<br />
<br />
“Finished” as there’s still some accessory compartments and such to be made.<br />
Unfortunately I ran out of contact cement so those may have to wait.<br />
<br />
<br />
<br />
Materials used in this particular project:<br />
<br />
(Metric.)<br />
<br />
6.5mm plywood:<br />
2pcs 1345*450<br />
2pcs 1345*70<br />
2pcs 1345*50<br />
2pcs 450*70<br />
2pcs 450*50<br />
<br />
Which roughly translates to 1.7 m^2<br />
<br />
<br />
Adam Hall:<br />
<br />
Extrusions (with miters):<br />
7mm Casemaker 6106<br />
4pcs 1347<br />
4pcs 452<br />
4pcs 54<br />
4pcs 34<br />
<br />
7mm hybrid lid 6102:<br />
2pcs 1365<br />
2pcs 610<br />
4pcs 470<br />
4pcs 209<br />
<br />
<br />
Hardware:<br />
2pcs 17295TP (locks)<br />
4pcs  4124 (ball corner)<br />
4pcs 4128 (stacking ball corner)<br />
4pcs 4053 (corner reinforcment)<br />
4pcs 4041 (corner reinforcment)<br />
4pcs 4905TP (feet)<br />
2pcs 2524 (strut hinge)<br />
2pcs 2602 (hinge)<br />
1pcs 3418 (handle)<br />
<br />
~170 4,8mm POP-rivets<br />
~20 5mm washers for reinforcment where the expanding end is on the plywood.<br />
<br />
Hard cellfoam frost insulation material for the interior.<br />
<br />
1L contact cement.<br />
<br />
Construction glue, 2 tubes.<br />
<br />
<br />
“Special” tools needed.<br />
<br />
Power miter saw, non sliding preferable for sturdiness.<br />
Power drill.<br />
POP-riveter.<br />
POP-rivet drill bit<br />
(electric angle-grinder)<br />
(center punch)<br />
<br />
<br />
Regards<br />
Sam</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>T-Bird</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9343-making-flightcase-epi-ltd-explorer-bass-long-big-pics.html</guid>
		</item>
		<item>
			<title>Admin. Squelch the damn SPAM please!</title>
			<link>http://www.marshallforum.com/backstage/9313-admin-squelch-damn-spam-please.html</link>
			<pubDate>Mon, 09 Nov 2009 19:17:47 GMT</pubDate>
			<description>Is there a baracuda or something on the head-in to block this traffic?</description>
			<content:encoded><![CDATA[<div>Is there a baracuda or something on the head-in to block this traffic?</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>MajorNut1967</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9313-admin-squelch-damn-spam-please.html</guid>
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			<title>Craigslist</title>
			<link>http://www.marshallforum.com/backstage/9295-craigslist.html</link>
			<pubDate>Mon, 09 Nov 2009 13:46:31 GMT</pubDate>
			<description><![CDATA[Have you guys noticed that everything sold in the "instrument" section of Craigslist is either "Rare", "Never Played", "Mint Condition" or "Vintage"?

Come on people.]]></description>
			<content:encoded><![CDATA[<div>Have you guys noticed that everything sold in the &quot;instrument&quot; section of Craigslist is either &quot;Rare&quot;, &quot;Never Played&quot;, &quot;Mint Condition&quot; or &quot;Vintage&quot;?<br />
<br />
Come on people.</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>StootMonster</dc:creator>
			<guid isPermaLink="true">http://www.marshallforum.com/backstage/9295-craigslist.html</guid>
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			<title>Jubilee social group.</title>
			<link>http://www.marshallforum.com/backstage/9245-jubilee-social-group.html</link>
			<pubDate>Fri, 06 Nov 2009 23:44:27 GMT</pubDate>
			<description>If anyone is interested:

http://www.marshallforum.com/groups/8-silver-jubilee.html</description>
			<content:encoded><![CDATA[<div>If anyone is interested:<br />
<br />
<a href="http://www.marshallforum.com/groups/8-silver-jubilee.html" target="_blank">http://www.marshallforum.com/groups/...r-jubilee.html</a></div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>Hollowbody</dc:creator>
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			<title>Watch What You Are Buying</title>
			<link>http://www.marshallforum.com/backstage/9195-watch-what-you-buying.html</link>
			<pubDate>Thu, 05 Nov 2009 05:28:31 GMT</pubDate>
			<description><![CDATA[About a month ago I wrote in and asked about the original speakers in a JCM 2000. I wanted to know what they were supposed to be as I was "thinking" about buying one. (My wife has put all of my toy buying on hold for now). Any way, I was on ebay and sent a message to the folks at Motor City Pawn and asked them "Can you tell me what brand and model of speaker is inside the amp?". Their response...get this..."How do I check? Thank you".:rofl: :laugh2: :rofl:]]></description>
			<content:encoded><![CDATA[<div>About a month ago I wrote in and asked about the original speakers in a JCM 2000. I wanted to know what they were supposed to be as I was &quot;thinking&quot; about buying one. (My wife has put all of my toy buying on hold for now). Any way, I was on ebay and sent a message to the folks at Motor City Pawn and asked them &quot;Can you tell me what brand and model of speaker is inside the amp?&quot;. Their response...get this...&quot;How do I check? Thank you&quot;.:rofl: :laugh2: :rofl:</div>

]]></content:encoded>
			<category domain="http://www.marshallforum.com/backstage/">The Backstage</category>
			<dc:creator>DC135er</dc:creator>
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			<title>So I am going to talk with Rob Halford....</title>
			<link>http://www.marshallforum.com/backstage/9194-so-i-am-going-talk-rob-halford.html</link>
			<pubDate>Thu, 05 Nov 2009 05:25:19 GMT</pubDate>
			<description><![CDATA[and this is what im going to ask

"what did you do with all your stage clothing from the 80s? are they in a box or something?"

well, I really recommend to check out rocklineradio.com its probably the best radio show ever made on earth. you can talk with a bunch of famous people, and its fucking awesome. I have already talked with nicko mcbrain there and yeah, its fucking awesome. AND ITS FREE!]]></description>
			<content:encoded><![CDATA[<div>and this is what im going to ask<br />
<br />
&quot;what did you do with all your stage clothing from the 80s? are they in a box or something?&quot;<br />
<br />
well, I really recommend to check out rocklineradio.com its probably the best radio show ever made on earth. you can talk with a bunch of famous people, and its fucking awesome. I have already talked with nicko mcbrain there and yeah, its fucking awesome. AND ITS FREE!</div>

]]></content:encoded>
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			<dc:creator>carnada</dc:creator>
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