How to Build Your Own Guitar Case

A case is essential to the well-being of any guitar. Though transporting a guitar alone is much lighter and less cumbersome, the chances of having it scratched, cracked or even snapped are not worth the stress. With elementary skills, tools and materials, a case can be built for a fraction of the cost of store-bought models.

Things You'll Need

• Tape measure
• 3/4-inch plywood
• Pencil
• Straight edge
• Circular saw
• Drill
• Countersink drill bit
• 14 hex-head, countersink screws
• 1/2-inch foam
• Felt-tip marker
• Utility knife
• Foam glue
• 3 butt hinges with screws
• 3 drawbolts with screws
• Guitar case handle
• 4 protective corner caps

Instructions

Cutting and Joining Wood

1. Measure the length, width and depth of the guitar. Use a pencil and straight edge to transfer the guitar measurements to the 3/4-inch plywood for three types of sections: lid, four sides and bottom. When marking the plywood, make each section 1 inch longer than the length, width and depth of the instrument to ensure ample room for the foam padding you will install later.

2. Cut out the plywood sections using the circular saw. When joined, they will form a long, rectangular shape.

3. Join the four plywood sides together and then to the bottom using the 14 hex-head, countersink screws. Use a countersink drill bit to predrill holes so that the plywood does not split. This will also enable the countersink screw to sit flush with the surface of the wood. Insert four screws on each of the short sides and six along the bottom.

Installing Foam Padding

1. Prepare to install foam padding along the inside of the case. First, measure and cut the 1/2-inch foam to shape using the utility knife. High-resilience foam is best. Mark the cut line with the marker and use the straight edge while cutting to ensure a straight cut.

2. Lay each piece of foam in position and then place the guitar inside. The guitar should fit snugly between the pieces with little or no play. Remove the guitar and foam and adjust the foam pieces as needed to ensure a snug fit. If the fit is good, apply foam-specific glue to the backside of all foam pieces and set the pieces in position.

3. Cut the foam to be mounted on the inside of the lid. Note that the lid foam should be cut with a 1/2-inch reveal (a foam-free space) along the perimeter of the inside of the lid. Glue the foam in position as in the previous step. The reveal will ensure the lid can completely seal without being obstructed by foam from the sides of the case.

Installing Hardware

1. Set the lid in position on top of the case. Join the lid to the body using three butt hinges. Predrill the hinge holes to avoid cracking.

2. Mount the three drawbolts. The larger portion of each drawbolt should be attached to the body at equal intervals on the long, open side of the case body. The smaller portion of the drawbolts will be attached to the lid along its side. Predrill each screw hole to avoid cracking.

3. Install the guitar case handle and protective corner caps. Position the handle below the center drawbolt on the case body. Predrill all screw holes to avoid cracking.

Tips & Warnings

• If a finish is preferred for the exterior of the case, apply it before installing any hardware.

• Purchase good-quality hardware to ensure the guitar stays inside the case.

References

• Project Guitar