[deleted]

You mean like a milk crate?

Sheet metal and pop rivets for the joints is the first thing I can think of.

Reinforced double wall polystyrene will give you a lot of strength.

What are you using if for? What is the weight of contents? Why not wood?

Corrugated plastic or HD corrugated cardboard.

EKO ply. It’s all recycled material or use plastic wood.

Lexan and epoxy? What exactly are you trying to do?

Aluminum square tubing and sheet metal. Rivets or screws.

Goodwill has used suitcases and plastic totes for dirt cheap every now and then.

Xps insulation. Just coat with a screen, and paint at the joints. Search YouTube for xps cabinets.

Like this? https://www.usmailsupply.com/P/202/CorrugatedPlasticMailTotesUSPSSize-1825Lx1325Wx115H-MinimumOrder6

As a sheet metal worker, I say buy a brake, another reason to purchase a new tool, and form your own Pittsburgs. No rivets necessary

[deleted]

Plastic sheeting of some kind of glue?

Fiber glass. But actually just get a hard suitcase from goodwill

Make the box walls out of an epoxy resin pour. And then connect them with more epoxy.

Recycled cardboard and paper mache the only cost will be the glue and paper mache is really sturdy when done properly

Sheets of ploycarbonate?

Origami!

Use angled steel and drill holes to put in bolts then sheet metal to join.

Wood is too heavy for the purpose of my projectS. The weight of the contents are already heavy And need protection. (Musical Instruments/Keyboards)

It's likely the exterior will take a beating.

<3 You know what, if I could make my project out of the plastic milk crate material, my whole LIFE would be set! But I need the walls of the box to be solid and custom dimensions. The size of the custom-built box would be larger than a suitcase.

Could you explain/expand on your point? I'm interested, BUT I'm also the polar opposite of well-versed in metal-working LOL.

I'm building a glorified box for my musical instruments and associated equipment. The details sound more confusing in text than they actually are. What you need to know is that it needed to be sturdy and lightweight. Also its dimensions are roughly 56 inches wide, 16 inches deep, and 12 inches tall. My 1.0 design is exactly those dimensions. It fits most of my needs except it's too heavy WITHOUT anything inside. Contents include a computer, power supply, other tech, and at least one 88-key midi keyboard.

LOL People, I don't actually need a suitcase. Goodwill is not an option, obviously. I'm building a big-ass box LOL. The box will be bigger than a suitcase and will be used to transport heavy, delicate, and expensive musical equipment. That's why I need a lightweight and durable material.

Okay I need a doctor. You blew my mind. The only question for you is: how much money will I dump out for a 54x16x12 inch box? How many gallons would I need?

will very seriously consider! if it's just as strong as wood, the only limitation I'll face is cost.

will very seriously consider! if it's just as strong as wood, the only limitation I'll face is cost.

probably not strong enough for the heavy equipment I'm using this box for. Sorry I didn't mention that in my original post. BUT, I will consider for future projects. Thanks!

Hmmmmm. This is a more than acceptable idea. Thank you! Will consider!

>Reply

This is a great idea. After doing some research, I'm highly considering this. The only thing I have to worry about at this point is cost of building materials. Apparently, a basic riveting tool is a footnote of a cost, which I'm happy to discover.

you know what, I've heard about Aluminum as an option before. If the cost of aluminum for the project doesn't break my bank account, I'll highly consider it. I've had some guys in the film industry tell me about it...... actually they raved about it lol.

not quite what I need for building custom-sized boxes.

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