Homemade fibreglass case

[pilagou]

I need a somewhat specific case. It needs to be waterproof (I live on the West Coast, and it rains a lot), it needs to be tough (that accordion travels on a cargo bike) and it needs to be reasonably light and small (because why not). So I have a new project. I plan to built a custom fibreglass case and I'm looking for ideas and advice.

My current plan it as follow:
1) Build a rough model of my accordion out of cardboard. It won't be perfect but I want to get the keyboard angle and size within half an inch. Then wrap it in parchment paper (the thing used in baking)
2) Add a layer of insulating board foam to create a foam shell around the cardboard model.
3) Shoot urethane foam on all the edges and connections and, once dry, carve the extra foam to get rounded edges and a good overall shape.
4) Hand lay the fibreglass directly on the foam (using epoxy). Probably something like 1/16 to 1/8 thick.
5) Once the fibreglass has dried, cut the whole thing in half along the keyboard line and remove the cardboard stub
6) Try the real accordion inside, carve the foam where and if needed. Add some urethane if and where needed
6) Rivet a sandwich of thin aluminum plates all around, a piano hinge on the back and some clamp catches on the front
7) Glue a thin layer of soft foam on the inside and then some velvet on the foam.
and that's it

I have some experience working with foam, fibreglass and metal. But that would be my first music instrument case. Anyone sees flaws or areas for improvement in that plan? I expect the whole project to be between $200 and $300

 

[Dingo40]

I need a somewhat specific case

Here's a past thread with a different take on the same topic:

Thread 'Initial review Pelican Storm Im2875 case'

Jan 14, 2022

In an effort to have the best chance of having an accordion survive on my boat this next summer I’ve decide to use a Pelican case. I used Pelicans website to determine which case would fit my full size accordions, adding a few inches to each dimension. I’m glad I did this because if I hadn’t there would not be clearance to use the included customizable pluck and peel foam. I ordered from Amazon with free overnight shipping for prime subscribers and it arrived this morning.

So far I’m satisfied that I made a good decision. I do wish I could have bought one slightly bigger so I could have...

• Ben-jammin
• Replies: 8
• Forum: Accordion Chat

• 

Pelican Case prices.

Google Search

They seem within your budget and a lot less trouble ?

 

[jozz]

how will it be waterproof?
You are cutting a 3D shape in half, and then?

given the budget I would suggest a second hand Pelican and the usual pluck foam to form the inside

 

[Ben-jammin]

I applaud the effort and would be interested how you proceed. I love my Pelican case but it is very bulky and heavy for general use. During the sailing season mine just stays on the boat.

Some things to consider is how are you going to create a water tight seal? A lip on the top half that overlaps the bottom might be an option in combination with a rubber gasket. But then if you manage to sufficiently seal it to be water tight you will have another issue in having a potential for the instrument sitting in a stagnant cavity that could have a dangerous moisture content depending on the humidity level when the instrument was put away. Also internal temperature should be considered, if it doesn’t breathe it could be worse for retaining heat than more conventional accordion cases(This is also a concern for my Pelican case). Maybe having some goretex windows to allow it to breathe some and a cavity with some moisture absorbing material would be a prudent step. Also painting it a color that does a good job of reflecting heat would be wise.

 

[Ventura]

if one wants waterproof as a primary goal, then i suggest
modeling after the pro Amp cases for like a fender twin
guitar amp

these have a molded base with wheels in which the amp can be set,
and then the molded top is lowered over it.

no amount of rain can get in, unless it sits in a puddle that turns
into a lake and the water level is 5 or 6 inches and is therefore
higher than the base

Anvil flight cases for Accordions, which are probably still available
by order, use the same design, just not molded.. You might find a
photo of Frank Morocco somewhere on the web traveling through
an airport and spot his Anvil case

i have several amp-style molded cases from Hercules from decades
ago (Musicorp distributed them) and they are nearly indestructable..
some are large enough to use for an accordion if one wants to customize
the interior with precise foam padding. i used mine for a big Yamaha PA head
and pre-mounted wireless recievers for decades

of course, clamshell more-or-less watertight luggage cases have
been in existence for half a century.. i used several of the huge Sampsonite
models and still have one

there are also large clamshell rolling general purpose SKB type cases
for various industries, you find them in like Pro Photo equipment catalogs,
i have one of these also.. they have the tooling to make welded dual channel
aluminum mating rims with an embedded rubberized material, so yeah,
pretty much waterproof, but will evenntually sink if the ship goes down

 

[pilagou]

Yes, I should have been more specific about my waterproof-level goal. I want the case to be able to withstand heavy rain and protect the accordion when properly positioned. But I don't expect the case to be waterproof (as in being able to safely float if dropped in a pool).
Really, what I want is a case made for transport. Something tough but light and small enough to be carried by hand, on a bike or on one's back. So square suitcases do not meet my expectation. I have two basic "suitcase" style cases and those things are not great to carry around. But I need something tougher than a soft case so that if the case were dropped or hit it would protect the accordion as well as possible,

 

[pilagou]

It's it the work.

I measured my instrument and built a cardboard shape


Then I coverer it in 1/2" closed cell rigid foam and glued it with urethane foam



Once the foam cured I removed the excess and sanded to a shape. Ready to glass



No pictures of the glassing process because super sticky gloves full of tacky epoxy aren't great to grab a phone. But once glassed I put the whole thing into a poor man's vacuum bag (in this case, garbage bag connected to a vacuum cleaner). This is to keep the layers of wet fiberglass and the foam pressed together while it cures.



And this morning the thing was hard enough to start working on it.



There are still LOTS of steps to go. Next ones are sanding, cleaning, correcting some defects in the glass and hinge install... To be continued

 

[jozz]

cooL!
how much does the shape weigh right now?

 

[pilagou]

cooL!
how much does the shape weigh right now?

Right now 3.9kg (8.6 lbs). I hope to keep the whole thing under 4.5 kg when finished. We'll see.

 

[pilagou]

More pictures. I cut the back, riveted a piano hinge section, cut the rest and it opened up



Back view with the hinge



And... now with the instrument inside



Lots of work remains to be done to finish both the inside and outside... but no major disaster to report (yet). The accordion fits snugly inside which was the whole point of going custom-made

 

[pilagou]

I was a bit short on free time recently. But there is still progress. The slow variety of progress. But that's still better than nothing. I recycled some old aluminum I had laying around for borders and stuff.

In the process of riveting one side border


With the latches and handle. I tried to keep things light when I could so relied a lot on thin aluminum epoxied and riveted


The inside is mostly functional too. But I don't have pictures. Tomorrow should be tape and paint day.

 

[pilagou]

Well, that's it, the thing is mostly finished. There certainly will be tweaks after some field use. It is 4.4 kg and the accordion it was built for fits super snugly inside.

The finish is rubberized paint (usually used for cars underside)



Inside I left it to the foam. I might add a layer of something one day if I find the right something. There are hard foam corners on the top that fit the shape of the keyboard. The accordion has some rather agressive metal feet so I added plates of thin aluminum glued to soft foam where they rest. This adds a little bumper and will prevent the feet carving themselves through the foam. I also added some aluminum on the sides where the accordion metal straps holders rest. The accordion fits exactly between the plates, no movement



The front panel is coated with very thick bubble wrap. I think this gives the accordion's "soft" side as good a protection possible. The case gently presses on the accordion when closed.



It can be loaded while standing or on its side...



Anyway... I'm sure there are better cases out there. Nicer looking ones. Tougher ones. Cheaper ones. But I'm still happy about this little project. Under 4.5kg, a bit under 300$ Canadian... (which is like 200$ US these days) and custom sized for my fancy accordion...

 

[Dingo40]

I might add a layer of something one day if I find the right something.

Great result!
Re lining the inside:
How about about felt?
Felt is available from felt dealers in various densities and thicknesses.
(Attached using spray on contact adhesive.)
The feet can rest on pieces of leather ( again, attached using spray contact adhesive.)
Very durable and shock absorbent (according to thickness), great finish.