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DIY fitted shotgun case

17K views 32 replies 25 participants last post by  Dewey Cox  
#1 ·
Anyone here ever make a fitted shotgun case? I’ve got a combo I’d like to have a case for but all the ones I can afford are shot and at the end of their lives. I’ve done quite a bit of woodworking in the past and have a full shop but it would be nice to have plans to start with and where to get the best materials.... padding, fur lining, corner protectors, handles, locks etc.... any pics of what you’ve built would be awesome too!
 
#2 ·
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!
 
#3 ·
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.
 
#4 · (Edited)
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.
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Once you have it, pull the bottom foam out and start doing some measuring.
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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.

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

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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.
 
#6 ·
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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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#8 ·
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
 
#10 ·
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.
 
#17 ·
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.
 
#18 ·
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.
 
#20 ·
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.
 
#25 ·
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.



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#27 ·
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.
 
#29 ·
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: