I’ll follow along with this one cause I’m curious as well.
I’ve thought about it many times, thinking my Americase would serve as a guide but weight has been my concern. Same reason I’m not a huge fan of said case.
Also thought about a wooden, double gun case that doesn’t require breaking down.
Good winter project material!

 

In 1982 I made a wooden fitted case to protect my gun while in transit to and from a competition in Australia. It survived all the attempts of various baggage handlers in London, Sydney and Brisbane, not to mention British Airways, to destroy it. I didn't have any formal plans for the design........I just made it up in my head. I made a rectangular box using 5/8" marine ply for the top and bottom and 1" pine for the sides........everything glued and screwed together. Then I ran the box lengthways through a band saw, fitted out the partitions in the base section, which I also glued and screwed in place and fitted a full length piano hinge along the long side. The inside padding in the case consisted of foam glued to the innards. I screwed steel corner protectors to all the external corners, added four snap over key locks and a handle and the thing was good to go after a lick of paint. The case was much too heavy for every day use so I sold it after returning to the UK.

 

I built a few wooden cases, they all got sold after a while as others wanted them more than I did. Solid wooden cases are generally pretty heavy.
Start with a Plano All Weather gun case, and go from there. It's probably the most versatile case I ever bought.

They are $69 at Amazon.

Once you have it, pull the bottom foam out and start doing some measuring.

Then go to the local building supply store and get one of the laminated tabletops about 1/2" and some 1/2"" x 3" x 36" poplar and oak for the dividers.

Lay the gun out with accessories and develop a layout for the dividers.

As you build out the box cover the bottom and dividers with the fabric of your choice and fit everything as you go. It's a lot easier to cover the pieces and then do the assembly than to get a good fit with the fabric after it's assembled.

I have two different trays for this case, one for the Citori Plus combo, and the other is setup for an 1100 and 4 barrels.
The finished case is heavy, but not as heavy as an Americase. Mine has been from the east coast to Tucson 10 times or more and the airline hasn't been able to break it yet.

 

I wanted a case for my bt-99 but couldn’t find one that I liked or in my budget. I came across an old sport locker case at a local gun shop but the inside was trashed. I ripped the guts out of it and redid it with foam and felt.


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i used two layers of 1 inch foam and laid out the barrel / forend and the receiver and then my choke case. Once I had everything arranged I traced out the parts and cut out the one layer of foam. Then I glued the two layer of foam together with spray upholstery glue them lined the case/ foam with felt and glued it all in.


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Unless you really enjoy building one, and don't mind the weight of a wooden case, buy an ABS case is a lot easier. And probably stronger.

 

Save yourself alot of trouble and get yourself a pelican 1700 case with wheels and a handle. If you want, do not buy the foam inserts, and custom make your own innards if you like. I decided to buy a boyt soft case and place my gun inside the boyt case,and then place the Boyt case inside the Pelican case for traveling to shoots. Once I arrive at the shoot. I leave the Pelican case in my room and travel back and forth to the club with the soft case. Its nice and light and holds everything I need. I place my shoot bag in my check on bag. Good Luck with building a wood case!!! You'll need it. break em all Jeff

 

That what Todd Bender uses, and I suspect he travels with his gun just about as much as anyone. Like the idea of having the soft Boyt case for the range too.

Did enjoy seeing the various DIY cases though.

 

If you don't care that it's a Beretta case, Beretta has the factory ABS combo cases on sale for $198.
Beretta Team Case, ABS Blue, Combo Over & Under Shotgun

 

Baggage handlers managed to damage the forend on one of ours through a gun case INSIDE a Pelican.

I still think they saw the “restricted item” tag and jumped on it.

I hate baggage handlers. As an FYI that’s why Eddie Van Halen designed a guitar with a 4/2 headstock, so it would fit in overhead baggage lockers.

Sadly not an option for us.

I have a home made wooden case. Very heavy. I do think Old Diabetics idea is probably the soundest. Build a box then slice it.

 

Baggage handlers managed to damage the forend on one of ours through a gun case INSIDE a Pelican.

I still think they saw the “restricted item” tag and jumped on it.

I hate baggage handlers. As an FYI that’s why Eddie Van Halen designed a guitar with a 4/2 headstock, so it would fit in overhead baggage lockers.

Sadly not an option for us.

I have a home made wooden case. Very heavy. I do think Old Diabetics idea is probably the soundest. Build a box then slice it.

Friends went to Hawaii for the State shoot, and while they were waiting to deplane, they saw the baggage handlers throwing gun cases around like they were trying to break them. The stewardess saw them looking out the windows and had a look herself. When she saw what was going on, she opened the escape hatch and yelled at them to smarten up.
By the time all bags and guns were collected, the baggage handlers were unemployed and the airline was trying to make sure that there was no damage to guns or cases and everyone was happy.

 

Great Job all of you . I need to redo one Beretta case ,the foam in the lid ( upper part ) somehow got "eaten " by something ( somebody ) . In general I do not like Beretta cases ,since the bottom does not have liner

 

I know you said you didn't like the weight, but Americase makes fitted cases, and can retro fit an existing case, even have a choice of upholstery velvet colors. Americase.com 1-800-972-2737

 

I've purchased cases for audio equipment from these folks - the unique thing they do is custom cut the foam for you. You can buy a case with custom cut foam or buy new foam for a case you already have - even one you build. Full line of Pelican or SKB cases as well.

https://mycasebuilder.com/cases-by-use/rifle-custom-foam-cases/

 

When I built my case I found the locks and handle at a suitcase repair store.

 

Wow - that baby looks indestructible!

 

Wood working aside, the best way to custom cut the inside foam is with a hot knife. Harbor Freight sells one in the 150W range. I think it was $25 bucks or so. An Exacto knife or other similar methods just makes a mess. I did a custom insert in a case for some of the electronics I needed to transport for work.

 

We built a couple of prototype really fancy cases in our sheet metal shop at work once. Originally it was going to be something the shop team could do if we were slow.
There were two styles of case, one was like an Americase the other was a John Hall style.
Whichever the style the base options were it had a powder coat finish on the outside that could be any color profile you wanted, continuous hidden piano hinge, high security keyed locks, a rubber gasket internally to help seal the case, an internal battery with a couple small LED's, the battery also had a USB port to the outside of the case to charge or phone or whatever else could be charged with a USB.
We were also going to have a travel option with GPS tracking abilities (but would also require a monthly subscription service to activate it since it ran on a cellular network).
The dividers for the first ones were plywood, but the plan was to do an ABS plastic "tray" that could be removed/replaced if needed. It was to have a soft but firm foam over the top of it and then line it with a velour like fabric in your choice of colors.

In the end the cost never penciled out and the project died.

 

I would get a case that I wanted on the outside. Then customize the inside.

Just for example maybe a Pelican case. Then take out the foam and replace it with kaizen foam. Trace my parts and slice on the line and then remove individual layers of the foam.

 

I've done all the above but the older I get this is what I do now.
Shotgun Travel Cases, Multi-shotgun Cases
These guys are great I've have a couple custom, like one for just barrels and one for just receivers charged me the standard case price.

 

What do you use to discretely carry a semi auto into a hotel?

 

I have a couple of these from Midway. They don’t scream ‘gun case’ especially when carried in the same hand as a suitcase.
MidwayUSA Waxed Canvas Takedown Shotgun Case 34 Olive Brown

 

The absolute best wooden gun cases I have ever seen was during my visit to the Tri County **** Hunter's Association located in Batesville, Indiana. I think they get them from some local manufacturer. Great place to shoot with great people and good food.

I am sure that forum member @SeldomShoots could fill you in on this so be sure and send him a PM.

 

Batesville... yeah, that rings a bell for some reason.

And really - that case is OK, but when your guns deserve the very best...

 

What do you use to discretely carry a semi auto into a hotel?

Use a Cabela’s or Boyt breakdown soft cast and either put it in your suitcase or put it inside a duffle bag to go into a hotel with it. You can also use one of the plastic golf bag cases with wheels.

 

I font know about airline travel but the peak ultralight combo case is reasonable at 149

 

The absolute best wooden gun cases I have ever seen was during my visit to the Tri County **** Hunter's Association located in Batesville, Indiana. I think they get them from some local manufacturer. Great place to shoot with great people and good food.

I am sure that forum member @SeldomShoots could fill you in on this so be sure and send him a PM.

Doc,

Thank you for the gracious words about Tri-County Coonhunters. Weather's getting better, so the guys at TCC hope to see you and your friends there again on a Thursday morning, or Friday evening 50 bird.

Batesville, IN is the home of the Batesville Casket Company. Its nice town, and an old company, but kind of dead at times.

P.S. I'll see if I can speak with one of the guys in management and marketing at BCC, to see if you can get a deal for upgraded cases for the Bi-Star line. :hand10:

 

I believe the Batesville Casket Company is in Mississippi, south of Memphis on Interstate 55. But maybe not, knowing where it's located is the last thing I need to know.