Clay Schaeffer's homemade "Wackywood" bending plywood mandolin case [Pictures] - created 02-08-2012
Schaeffer, Clay - 05/21/2005.21:59:08
Here are some photos of a simple way to make a hard case.
The first photo shows one way to find the size needed for the body by wrapping it in the foam padding that you will use, then a layer of wacky wood (bending plywood) and tracing around the outside on to what will be the bottom of the case. In the background is a mandolin case that is a little further along.
The second photo shows the case with the "neck" portion added and the bottom tacked and glued on. I used 1/2 inch plywood for the neck portion. Make sure you have plenty of depth so you can pad the top and bottom of the case as well as the sides.
The third photo shows the top glued and stapled on, the edges routed flush, and a quick sanding. At this point I let the glue dry. Tomorrow I will saw the box in half on the tablesaw.
"Wacky wood" and bending plywood are actually different products. Wacky wood is 3-py, bending plywood is 2-ply. You used 3-ply, right?
Clay, do you need a special hinge for the neck part, How do you install it?
The picture in post 13 is showing the box after it has been cut in half on the table saw. I start on the small end with the box standing on end and the blade only raised enough to cut through the plywood (1/2 in.) I then lay the box on it's side and raise the blade all the way up. There are times when the portion of the box being cut is off the table, and a tall fence would be a help. Always remember to keep pressure on the fence. I then roll the box right around until I have sawn it in two. In the picture you can see the foam padding being glued to the material. Cheap carpet padding would probably work better (more compressible) but I used what was free(like the rest of the materials). I used elmers spray glue to adhere the cloth to the padding. I like it because it doesn't stick too well and allows repositioning the fabric for those of us who can't get it right the first time
Post / picture 14 shows the box with the lining and hinges temporarily installed. Once I scrounge some covering material I will wrap the outside around the edges and then glue the lining in permanently. Under the upper hinge is a wedge of wood. This is used to keep the hinge in a straight line with the lower hinge so they will work properly.
Hi Deb,
The bending ply I used has two thicker layers with a thinner layer between with the grain all running in the same direction. I've heard it called "wackywood" colloquially.
Hi Alain,
With a guitar you can often align the upper and lower bouts with the head and use three hinges. But this is a simple method of case making so I just used a little wedge.
This is essentially the same method the coffin cases used, except most used straight boards and mitered corners.
The part I think would be tough is doing the Apolstery (sp) and fitting inside. No idea how to do that.
It's easy. A simple staple gun, spray adhesive, maybe some decorative tacks around the edges, and some minor cutting for the corners is all you need to do.
The only college degree I ever finished was in upholstery, and I've made a half dozen cases that way, no sewing needed.
Any particular source for wackywood or flexible plywood in the eastern US?
Jim
Boulter Plywood in Somerville, MA carries both, they sell half and quarter sheets and will ship via UPS. Good people to deal with.
Thanks, Deb, for the source. I assume that the 3/8 Wackywood -- such a strange name -- would be good for a case, as mentioned above. I would also think that it might need to be reinforced at various locations, possibly on the edges or with some sort of internal struts.
Jim
Hi Jim,