Blog Layout
No Handle On The situation
Jul 30, 2020
Hardcase 48 - Hardware case that chews fingers...
First up on the workbench this week a wonderful illustration of the kind of job that just keeps getting put off. This case has become notorious among the band's crew due to it's complete lack of handles on either end. In their place is a wonderfully sharp jagged plastic where the handles previously were. But between tours the case contains the hardware and goes back into storage, shipping it off for repair is uneconomical, but the rest of the case is in good condition. The wheels run smoothly, the straps and buckles don't come open when not asked to and one of the missing handles is still lurking inside so a repair is definitely worthwhile.
So from a large sheet of HDPE a couple of pieces cut to fit and then a bending jig was cobbled together. A hodge podge of clamps, wood and the trusty heat gun used to form the end panel so it follows the shape of the case and sits under the lid. This shape is important as it transfers some of the stresses from the handle up into the lid which is secured by the straps on top.
After keying both sides with sand paper a liberal application of contact adhesive and then the replacement panel gets clamped up in place. A pattern of rivets is drilled out and a combination of regular and wide flanged pop rivets are attached to the face and also under the lip of the lid. The central rivet at the top is omitted until the two holes are drilled and the ends of the handles fed through. One found in the bottom of the case still attached to a piece of fractured plastic and the other a fresh vibrant part grabbed from the box of assorted spares.
With the ends secured with a rivet and a large washer the case is ready to be loaded back up again and the fingers of stage hands are safe once more.
First up on the workbench this week a wonderful illustration of the kind of job that just keeps getting put off. This case has become notorious among the band's crew due to it's complete lack of handles on either end. In their place is a wonderfully sharp jagged plastic where the handles previously were. But between tours the case contains the hardware and goes back into storage, shipping it off for repair is uneconomical, but the rest of the case is in good condition. The wheels run smoothly, the straps and buckles don't come open when not asked to and one of the missing handles is still lurking inside so a repair is definitely worthwhile. So from a large sheet of HDPE a couple of pieces cut to fit and then a bending jig was cobbled together. A hodge podge of clamps, wood and the trusty heat gun used to form the end panel so it follows the shape of the case and sits under the lid. This shape is important as it transfers some of the stresses from the handle up into the lid which is secured by the straps on top.