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An interesting concept for building cases
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Author:  unkabob [ Sun Dec 23, 2012 1:13 pm ]
Post subject:  An interesting concept for building cases

I like to build cases for the ukuleles that I build but am aware that there is a flaw in my newest idea. My concept is to form a case around the instrument or a mold made of several layers of aluminum foil joined by epoxy glue. It would be much like building the case of papier-mache'. I realize that the hinge-points and handles require reinforcment but I am not sure whether the whole case needs some kind of stiffening and what would work.

I feel like I am on the edge of a good idea but it needs work. Any thoughts would be appreciated.

Bob :ugeek:

Author:  Quine [ Sun Dec 23, 2012 1:39 pm ]
Post subject:  Re: An interesting concept for building cases

Foil and epoxy?? I guess it would work but sounds really messy.
Reinforcing only depends on how strong you want it. Cases range from padded fabrics up to steel. How strong are you looking for?

Author:  douglas ingram [ Sun Dec 23, 2012 1:44 pm ]
Post subject:  Re: An interesting concept for building cases

Bob, if you really want to pursue that approach, I'd suggest wrapping the the uke with lots of plastic wrap, the use expanding spray foam to get the shape. Once set, cut it apart, then shape and glass the foam.

Author:  unkabob [ Sun Dec 23, 2012 2:01 pm ]
Post subject:  Re: An interesting concept for building cases

Douglas:
I have the feeling that the wall has to be deeper than foil to give some rigidity and puncture resistance. If I can solve this problem, building a case would be a one or two hour job with no jigs or equipment required.

Bob :ugeek:

Author:  nyazzip [ Sun Dec 23, 2012 2:25 pm ]
Post subject:  Re: An interesting concept for building cases

http://www.youtube.com/watch?v=M3mYgzY5UAI

Author:  Clay S. [ Sun Dec 23, 2012 6:42 pm ]
Post subject:  Re: An interesting concept for building cases

For a ukulele I think bending a piece of wacky wood, using 1/8th inch plywood for the front and back, and a single layer of fiberglas would be quicker and easier than foil and epoxy.

Author:  Imbler [ Sun Dec 23, 2012 7:29 pm ]
Post subject:  Re: An interesting concept for building cases

Bob, Douglas's suggestion would give you a very strong case. Build the shape from expanding foam, file/rasp for smoothness, than fiberglass both sides of the foam. It will be extremely strong and light. Kit airplanes are built using this method,
Mike

Author:  unkabob [ Sun Dec 23, 2012 9:41 pm ]
Post subject:  Re: An interesting concept for building cases

Clay:
I have built a few cases of veneered fiberboard. They look pretty good but they are a bit heavy. They take me a day or two to build but are solid protection. I use urethane parkay-floor glue as kerfing , like a fillet weld, and it works well.

Mike:
I am stii trying to get my head around the process of Douglas's approach. When do I cut the foam to remove the ukulele? Will the foam itself have enough strength to be fibeglassed without flaking apart. I am still thinking about it.

Bob

Author:  Clay S. [ Mon Dec 24, 2012 6:36 pm ]
Post subject:  Re: An interesting concept for building cases

Hi Bob,
If you are looking for light weight you might try using 3/8 inch thick white pine for the sides and 1/8 inch plywood for the top and bottom. I have built some "coffin" cases for guitars using 1/2inch thick pine for the sides and 1/8 inch plywood for the top/bottom and they are relatively light weight and reasonably strong. For a uke a simple trapezoid shape would work fine. A tiny romantic guitar I have came in a trapezoid shaped case.
For the guitar cases I used butt joints, titebond and a brad gun to nail them together while the glue set. They went together pretty quickly. I made the case and lid in one piece then cut them apart on the tablesaw.
The foil and epoxy sounds like an interesting approach. I wonder if you could make your case from corregated cardboard then laminate the foil and epoxy to it to add strength and waterproofing?

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