Make your own guitar case: In the shape of a small coffin!

Coffin-shaped guitar case conceptual view.

Making a guitar case in the shape of a coffin is certainly doable; and it really doesn't seem like it should be all that difficult. Of course, it might end up being a little heavy; this one being made from wood.

Measure the guitar to be fitted; length, width, and height. Draw a coffin-shaped sketch similar to the one in the sample graphic. Allow about one inch all around the dimensions you took; and plan your coffin-case accordingly. For example; if your guitar measures 22 inches wide by 36 inches long by 7 inches high, you should plan to make the case at least 24 inches wide by 38 inches long by 9 inches high; to allow for some foam padding to be installed inside. The "cover" for this case will fit over the box itself, like a hinged shoe-box cover. Thus, the top piece must be made larger all around the box section. Plus, some of the lip needs reinforcement strips, for the hinges and latches; so that also adds to the dimensions needed. I'd suggest allowing at least two material thicknesses. The cover should have a 1 3/4 inch lip all around, to fit over the case sides like a shoe-box cover. Plan your cover pieces accordingly.

Layout, cut, fit, glue the pieces.

Using 1/4 inch thick plywood, layout and cut the bottom, top, sides, lips, and ends of the case and cover sections, according to your dimensions. Note that you will need to make the case sides and the cover lip sections wider or narrower than what your finished dimensions should be; based on preferred method of making the joints; i.e., with an inside or an outside fit to the main case bottom and case cover pieces.

Glue and clamp the sides, ends, bottom, cover, and lip sections, to create the basic coffin-shaped box and the shoe-box style cover. Be sure the side pieces are at 90 degree angles to the top and cover pieces, when assembling and gluing them. Allow to dry for eight hours or more. You can also cut and glue the hinge and latch reinforcing strips, and the handle reinforcing block, as shown in diagrams. You will need some 2" or 3" PVC pipe sections; wrapped with foam; to fit into the guitar curves, as shown in the diagram. You can glue these to the bottom of the case with contact cement. You might also want to glue a cap onto it for a finished look; or, you can leave them open, for storing guitar picks, strings, and the like. If you choose that, you might want some kind of elastic cover so things stay inside when the case is being carried. You will also need to make some type of support for the neck of the guitar; perhaps from 1/2 inch plywood. Create a "cradle", then glue or screw that to the bottom of the case; located according to your guitar dimensions.

Once the glue is completely dried, remove the clamps and begin sanding and finishing the case and cover sections; carefully blending and rounding all the sharp corners to be smooth and soft.

If you plan to stain or clear-coat your guitar case, it probably should be done at this point; once you've sanded and finished the pieces. Whether you choose to stain your guitar case or keep it natural looking, you should apply at least two coats of poly-urethane (or equal) finish coats in your choice of sheen (glossy, matte, flat); lightly sanding between coats.

After the finish is dry, you'll need to install foam padding inside, as well as some additional components, to help keep the guitar safely and securely protected when the case is closed and being carried and otherwise handled. Home Centers and hardware stores generally carry a selection of foam materials you can choose from. I'd recommend something other than plain polystyrene ("styrofoam"); if you look inside some of the tool boxes sold at the Home Centers, you will see the kind of material they use for protecting and securing items inside. Even carpet padding foam would do the trick, though you might want something a little thicker. Keep in mind what your overall finished inside dimensions of your guitar case are, in relation to the guitar itself; to ensure the thickness of the foam you select is not going to shrink the inside of the case too much; else the guitar will not fit properly.

Install hinges, latches, and handle.

Cut, fit and glue the foam all around the inside of the case; and inside the cover as well, except no foam inside the lip of the cover; only inside the cover panel itself. Place the cover (with foam) onto the case; install three hinges along one of the long sides of the cover and case assembly. On the opposite long side, and the shorter section as well, install three "suitcase-latches". For best results, use short screws with nuts and washers; through the reinforcing strips inside.

Install a purchased or fabricated handle on the latch side of the case so when it is being carried the latches are facing upward. You will have to test the location of the handle with the guitar inside. Be sure you have the 1/2" plywood backer-block inside the case to reinforce the handle location.

It would also be a good idea to install some sort of "feet"; on the bottom flat surface, as well as on the long side where the hinges will go; to protect the finish when the case is set down on the floor or other surface. Home Centers and Hardware Stores usually carry a variety of self-stick furniture "glides"; generally used on furniture legs, to protect floors. Check the thicknesses available; those might work just fine, and they're easy to install, too.

Tips & Warnings

• Since this shape is not "fitted" to the guitar shape, you can use some of the excess space for storage. Fabricate or purchase storage cases to fit into the available areas, as shown in the diagrams. Glue them to the bottom of the case.
• Be sure to check your dimensions, and keep in mind the added thicknesses for reinforcements and other components.
• Note: 1/4 inch plywood weighs about 25 pounds for a 4 ft. by 8 ft. sheet (32 square feet); or about 0.78 pounds per square foot. You can estimate the approximate weight using these figures; which will vary according to the size of the guitar and other variables. Don't forget to add the weight of the reinforcing blocks and PVC pipe and the foam (and of course, the guitar itself!).
• Some products used for woodworking are considered mildly toxic or hazardous.  For more product ingredient information, click the link below.

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