How to Make a Wooden Case for a Tenor Saxophone

For decades the tenor sax has played a role in popular music, from 1920s jazz to contemporary swing and dance. It is one of the larger members of the saxophone family. Here's how to make a case for a tenor sax that will protect it from dents and scratches.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Hardwood Sheets, 1/4 Inch Thick
• Saw
• Sandpaper
• Nails
• Hammer
• 16 1-Inch L-Brackets
• Screws For L-Brackets
• Wood Glue
• Clamps
• Varnish
• Block of Foam, 30 inches by 20 inches by 12 Inches
• Block of Foam, 30 inches by 20 inches by 2 Inches
• Pencil
• Craft Knife
• Fabric Gue
• Drill
• 3 Hinges, 1 1/2 Inches
• 2 Latches
• Handle

1. Cut your hardwood sheets into panels of the following sizes: two panels of 20 inches by 30 inches; two panels of 2 inches by 20 inches; two panels of 2 inches by 30 inches; and two panels of 20 inches by 12 inches. Sand the edges.

2. 
   L-bracket

   Nail the 2-by-30 panels to the 30-inch sides of one 20-by-30 panel. Nail the 2-by-20 panels to the 20-inch sides of the same panel. Nail the sides together where they meet. Put one L-bracket in each corner, about 1 inch from the bottom of the wood, and screw in. Run a line of wood glue down each corner. Clamp all of the edges and let the glue dry. This will be the lid of your case.

3. Nail the two 12-by-30 panels to the long sides of the 20-by-30 panel. Nail the two 12-by-20 panels to the short sides of the 20-by-30 panel to form a box. Nail all of the sides together. Put three L-brackets in each corner: the first one 3 inches from the bottom of the box, the second one 6 inches from the bottom and the third one 3 inches from the top. Run a line of wood glue down each corner. Clamp all of the edges and let the glue dry.

4. Sand and varnish or decorate the case as you like.

5. 
   Foam block

   Place the sax on the larger foam block and trace a line around it, including a margin of about 1/8 inch. Remove the sax and use the craft knife to cut out the tracing so it is about 10 inches deep. Place the sax in the foam to make sure it will fit; if you need to remove more foam, use the craft knife to do so.

6. Glue the foam block into the bottom of the case and allow it to dry. You can also cover the foam with fabric if you like, also using fabric glue.

7. 
   A locking latch

   Place the lid on the bottom of the case and line up the corners. Use the drill to put three hinges on the back of the case: one each on the left, right and center. Put the handle on the front of the case on either the lid or the bottom, however you prefer. Put the two latches on the front of the case, on the right and the left.

Tips & Warnings

• If you want to be able to lock the case, use locking latches in Step 7.
• Always wear safety glasses and gloves when working with saws and drills.

Resources

• Adding flair to your case with exotic hardwoods
• Working with varnish
• Getting foam by mail