Welding and Metalworking - Aluminum Extrusions

I'm not a metal worker. Much more of a woodworker.

I would like to make a couple of aluminum flight cases. Does anybody know where I could buy the extrusions, corners and hardware retail? I've found several web sites willing to sell large quantities wholesale, but nothing for a do-it-yourself project.

Thanks in advance.

What kind of cross-section are you looking for? How determined are you to get a particular cross-section? Those will be important issues.

One thing I'd try is stopping by a couple of screen door places.. if you can make friends with them they might order what you need along with their next order. Look in the yellow pages under aluminum fabrication, call some and see if they're friendly. Donuts or beer can benefit you far beyond their cost, just judge which is appropriate for the place you're buttering up.

A good junkyard is also a possibility. You'd be surprised at what turns up in junkyards..

lp

We had a chain called "Metal Supermarket" geared to such requests... it never got enough business. :(

Most building supplies places ...hardware stores, remember those?... have a metal section. But the prices are ridiculous. Aluminum is pricey as it is.

Scrapyards put aside good clean material, and, nice thing about aluminum is unlike steel it won't be rusty after a month in the rain. On the other hand, all the scrapyard aluminum I've seen is scratched. They will charge by weight, or, look you over and suggest what you should pay.

A simple L, 1" x 1", 1/8" thick, is really common.

If it's plain (not anodized) it will nick and dent easily, and refuse to hold a uniform sheen.

Thanks for the suggestions.

Here's my theory... There a lot of small companies making flight cases. They must be getting their parts somewhere. If one of them is willing to sell them to me in small quantities I'll have it made. It looks like they go together fairly easily with pop rivets.

I want to make guitar cases for odd sized guitars. Custom cases are ridiculously expensive and the wooden cases I have built are too heavy. In theory, aluminum would solve my problems, but I want to buy the parts. I don’t have the time or the skill to fabricate everything.

I know you don't have much time, but man, fibreglass seems ideal here.

I know you don't have much time, but man, fibreglass seems ideal here.

Good call. I agree.

lp