DIY - Re-design Road Case From Slant Top to Flat Top

TwinSpinDJ

Up-lighting
The beginning of this thread are Posts that I made to DJ Bobcat's "Re-Working My Large System", they are thread extracts from Bobcats thread. Hopefully, this one won't take as long. LOL Bobcat did a superb job of re-working his system. For background, see these posts:

Here are my initial postings from DJ Bobcat's Posting Re-Working My Large System. They have been linked here.

Today at 1:09 AM
#537


Bobcat...I started downsizing my small road case today; all external hardware and mounting two 4 space vertical mounting rails. Peeled back most of the black carpet that was attached to the sides of the road case so I can mark for cutting...next week. Headed out of town for wife's B-Day present (Beach trip).

I have a problem with the front and rear horizontal braces (wood) that stabilize the road case. When constructed they were recessed and glued (no screws)! I can't cut down the sides because the wood braces interfere with a straight cut. So, I'm going to cut the two braces off flush with the sides and then try to extract (chip or chisel) the indented leftover piece of brace, but not all because I will make the width of the brace footprint smaller. I don't know why they didn't just screw the braces from the outside. I mean they were covered by carpet anyhow. :sqeh: I'll take a picture of the case tomorrow before I begin. I may use screws to secure the braces, but won't use 3/4" plywood...maybe oak or some other hard wood.
On second thought, I may just cut the braces along their vertical edge to the width I want, then sabre saw horizontally from side to side. What's left will be enough to stabilize the case. You will understand better when I send the photos.

Last edited: Today at 1:19 AM
Today at 5:02 PM

#542

Bobcat...here are some photos of beginning of my project.


Carpet removed but still attached to bottom. Horizontal line in 1st Row, Picture 3 is where I was going to cut, but decided I needed more height to accommodate the foldout piano hinged lap shelf. You will see in subsequent photos where the revised cut line has been inscribed. Photo #3, above, shows the rabbited wooden support rail for the front of the road case. The support rail will be narrowed or deleted altogether.

Below photos are of equipment installed for measuring purposes. The CD Mix II is sitting on a metal rack shelf (19" x10.5"); however, it doesn't have a front support edge to keep the CD Mix II from sliding forward. I've got to find a remedy. Also, the wooden front support brace for the case will need to be cut down or completely removed. I wonder if the 7" rack rails will be enough IF the support brace is removed? Also, I need to reduce the size of the rear wooden support brace, too.
Picture #4, above, shows the two cut lines for flattening the top of the road case. The line closest to the CD Mix II was the initial cut line. The line above it is the revised cut line (runs from the front top edge of side). The Clamps in the pictures are temporary supports for determining horizontal cut lines and for temporary support for the Laptop shelf (piano hinged), next photos. Size of laptop shelf when open is 11-inch x 19". When shelf is closed it is 6".

Next #4, above, shows the current method of securing shelf to sides of the road case (upside down). I may use a wooden 1.5" x 1" piece of wood to support and secure the shelf, but that means adding more weight. Also, I may move the wooden support brace up to support the Laptop shelf when it is full extended. Seems like a good idea? Although it will be narrow in height than what is now shown.

Well that's all for today. I'll await comments and questions before I actually do an CUTTING. Kind of like measure 3 times but cut only once. LOL!

Oops! Somehow all of the photos that I uploaded got re-posted. Sorry~

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Last edited: Today at 6:35 PM
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DJ Bobcat

DJ Extraordinerror
Nov 8, 2014
10,830
Oklahoma City
This oughta be FUN! Good luck. I know you'll do a great job! Now I just need to take a little time to digest all those pics you posted.


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DJ Bobcat

DJ Extraordinerror
Nov 8, 2014
10,830
Oklahoma City
The beginning of this thread are Posts that I made to DJ Bobcat's "Re-Working My Large System", they are thread extracts from Bobcats thread. Hopefully, this one won't take as long. LOL Bobcat did a superb job of re-working his system. For background, see these posts:

Here are my initial postings from DJ Bobcat's Posting Re-Working My Large System. They have been linked here.

Today at 1:09 AM
#537


Bobcat...I started downsizing my small road case today; all external hardware and mounting two 4 space vertical mounting rails. Peeled back most of the black carpet that was attached to the sides of the road case so I can mark for cutting...next week. Headed out of town for wife's B-Day present (Beach trip).

I have a problem with the front and rear horizontal braces (wood) that stabilize the road case. When constructed they were recessed and glued (no screws)! I can't cut down the sides because the wood braces interfere with a straight cut. So, I'm going to cut the two braces off flush with the sides and then try to extract (chip or chisel) the indented leftover piece of brace, but not all because I will make the width of the brace footprint smaller. I don't know why they didn't just screw the braces from the outside. I mean they were covered by carpet anyhow. :sqeh: I'll take a picture of the case tomorrow before I begin. I may use screws to secure the braces, but won't use 3/4" plywood...maybe oak or some other hard wood.
On second thought, I may just cut the braces along their vertical edge to the width I want, then sabre saw horizontally from side to side. What's left will be enough to stabilize the case. You will understand better when I send the photos.

Last edited: Today at 1:19 AM
Today at 5:02 PM

#542

Bobcat...here are some photos of beginning of my project.


Carpet removed but still attached to bottom. Horizontal line in 1st Row, Picture 3 is where I was going to cut, but decided I needed more height to accommodate the foldout piano hinged lap shelf. You will see in subsequent photos where the revised cut line has been inscribed. Photo #3, above, shows the rabbited wooden support rail for the front of the road case. The support rail will be narrowed or deleted altogether.

Below photos are of equipment installed for measuring purposes. The CD Mix II is sitting on a metal rack shelf (19" x10.5"); however, it doesn't have a front support edge to keep the CD Mix II from sliding forward. I've got to find a remedy. Also, the wooden front support brace for the case will need to be cut down or completely removed. I wonder if the 7" rack rails will be enough IF the support brace is removed? Also, I need to reduce the size of the rear wooden support brace, too.
Picture #4, above, shows the two cut lines for flattening the top of the road case. The line closest to the CD Mix II was the initial cut line. The line above it is the revised cut line (runs from the front top edge of side). The Clamps in the pictures are temporary supports for determining horizontal cut lines and for temporary support for the Laptop shelf (piano hinged), next photos. Size of laptop shelf when open is 11-inch x 19". When shelf is closed it is 6".

Next #4, above, shows the current method of securing shelf to sides of the road case (upside down). I may use a wooden 1.5" x 1" piece of wood to support and secure the shelf, but that means adding more weight. Also, I may move the wooden support brace up to support the Laptop shelf when it is full extended. Seems like a good idea? Although it will be narrow in height than what is now shown.

Well that's all for today. I'll await comments and questions before I actually do an CUTTING. Kind of like measure 3 times but cut only once. LOL!

Oops! Somehow all of the photos that I uploaded got re-posted. Sorry~

Attachments
Last edited: Today at 6:35 PM
"
I see what you're doing there Twin... I think your cut lines are fine. I know you're worried about adding weight with the bracing, but it probably won't be that much weight, and remember you're already taking quite a bit of weight off, when you take the slanted top off. As for securing your CD Mix II, maybe you could do what I did to secure my Nano PC's to the metal rackmount shelf... The feet were screwed on, so I removed the feet and with slightly longer screws, I drilled matching holes in the metal shelf and used the same screw holes to mount the computers. They were pretty thin screws, though, and I broke one off when tightening too tight. Took me an hour to get the broken part out of the hole.



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TwinSpinDJ

Up-lighting
Bobcat, I'll do some more thinking regarding securing the CD Mix II. I will need to reduce the size of the front wooden brace because it is a bit uncomfortable moving the lower controls on the Mix II. Unfortunately, I want to be able to remove the Mix II from the road case without too much trouble. I use it by itself when I do Karaoke with it and only my laptop and external sound card.
There should be a weight trade off when cutting down the sides, but I don't believe it will be huge. Won't get back to work on project for 8 days from now, so don't look for any news on work getting done. Thanks for comments.
 

Proformance

DJ Extraordinaire
Nov 6, 2006
3,264
It's easier and faster to build a new road case than to try and change an existing one.
 

TwinSpinDJ

Up-lighting
You may be right, but I'll give it a try...and if doesn't work out, I have all the hardware to begin anew, including the vertical and horizontal rack rails.
 
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DJ Bobcat

DJ Extraordinerror
Nov 8, 2014
10,830
Oklahoma City
You may be right, but I'll give it a try...and if doesn't work out, I have all the hardware to begin anew, including the horizontal rails.
If you're like me, it's not really about what's faster or easier. It's faster and easier to just go buy one that's already done... but then you'd still have the one you DIDN'T modify. So do you sell it???... Give it away???... Toss it in the trash??? I like to reuse what I already have before I go buying (or building) something new. It's the "GREEN" thing to do.
 

TwinSpinDJ

Up-lighting
Unfortunately, I'm in no hurry and don't need to spend additional money; already purchased a shelf 19X10.5" from Y.D.I. for purpose of re-designing the case in point. Nevertheless, good advice for the moment.
 
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TwinSpinDJ

Up-lighting
Well, the road case is completed and had first baptism this past Saturday night. Small wedding reception on open deck along marina and river. Venue is call Chart House Restaurant. It was a small intimate reception with no more than 40 in attendance. Picture of Bride and Groom doing their First Dance (second marriage for both).

You will see the road case (back and side view) at the venue. However, I forgot to take pictures of the road case when I got home...to tired. Anyway, here are a few shots looking into the wall unit storage space. The TOV case is for larger events.

Christine-Phillip 1st Dance.jpgDJ Setup--prior to Arr B&G.jpgFront View of Sm Rd Case--Wall Unit Storage.jpgRt Side View Rd Case.jpgFr View--size thickness of fr cover.jpg
 

DJ Bobcat

DJ Extraordinerror
Nov 8, 2014
10,830
Oklahoma City
Well, the road case is completed and had first baptism this past Saturday night. Small wedding reception on open deck along marina and river. Venue is call Chart House Restaurant. It was a small intimate reception with no more than 40 in attendance. Picture of Bride and Groom doing their First Dance (second marriage for both).

You will see the road case (back and side view) at the venue. However, I forgot to take pictures of the road case when I got home...to tired. Anyway, here are a few shots looking into the wall unit storage space. The TOV case is for larger events.

View attachment 34730View attachment 34731View attachment 34732View attachment 34733View attachment 34734
Somehow missed this earlier. Looks good! Good job... and SO quickly.


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