I have a customer that wants a lightweight box, it will be about 13" wide, 6" deep by 42" long.
This customer is a friend of the family that practices various martial arts, he has various practice weapons that he takes with him to the training center. Now he is using a bag, but it does not work well for some of the weapons, and it does not protect the weapons from being banged around.
The weapons are made from aluminum, and are EXPENSIVE to buy, they are only used in Kata, not stuck against anything, so they are fairly lightweight and somewhat fragile.
My plan, thus far, is to make the corners of the box from some hardwood, I have Ash on hand so I'll go with that, and the flats of the box from some nice 4mm thick plywood (5/32"?).
The box will be about 4" deep on the bottom half and 2" deep on the top half, both halves will be used for stowing weapons.
This is the joint I have worked out, I think it should be strong enough, I want to only glue it, no fasteners................
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The lip of the box also gets a strip of hardwood.
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The outer edges will be rounded over on the router table (as soon as I put new bearings in my Hitachi M12 router!!).
Do you think that regular Yellow carpenters glue will be good enough for this?
I do have some Gorilla glue, but I've not used it much, and when I did, it was not the best of times
This is just a mock-up that I made to see how it would work, it is tacked together with some CA glue, the joints are not PERFECTLY tight etc, but it will give you some idea of the way it is designed and made.
Hints, suggestions etc please!!