I’ve been making a mandolin travel case out of reclaimed lumber and metal. It’s been a very slow process; the two panels I made last autumn. Then, because my workshop is unheated and everything involved lots of materials, I didn’t work on it again until this summer.

The bottom panel is oak, made of boards unsuitable for a hallway floor, glued against some quarter-inch ply. The top panel is ply plank, salvaged from an abandoned bed, also glued against quarter-inch ply. Both are fit into grooves routed into the side-boards, all around the case, about a quarter-inch deep. The side boards are from several sources, including some disassembled Mr. Fixit work (circa 1958), a bit of what was once part of a rough-cut framing 2×4 from the house’s back addition (circa 1924), and leftovers from projects of mine. The corners are biscuit-joined, as you can see here:

top and bottom halves

This second picture is after more sanding than I want to talk about, two coats of wood hardener, two coats of stain (pro tip: wood hardener says you can stain or paint after hardener application; one of those actually works; hint: not staining) and two coats of polyurethane. Each coat has multiple hours of materials time (drying time, soaking time, etc) before you can do the next layer; so did each round of gluing, before. The polyurethane has three days of drying time after final coat.

as though hinged together

You can start to see why this takes a while.

I have a sense of accomplishment with it, as well as some learning; I’ve had to re-do a couple of parts of it here and there, like the top section’s entire set of sideboards, and part of the oak panel. But I’m to the point now where I want the damn thing, f’srs. I’d lake to take it with me to VCon.

Monday, I can finally start attaching hardware – latches, hinges, metal trim to protect edges (all new), metal braces for the interior, like the one below, which was reclaimed earthquake strapping:

hammered to L and back ar ar ar ar ar

This case will get beat up, cosmetically, out on the road. I’m fine with that. But I want it to be no fucking around strong, to protect my mandolin.

At the same time as the hardware, I should be able to fit the divider panel on the inside, for a little storage section, like my zouk travel case has. That’ll involve Materials Time again (dammit) but not very much.

I’m really looking forward to putting in the foam. That’s the last part. This project has gone on long enough.