Wooden Coffin Case

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Project by GeneR posted 09-08-2013 09:47 PM 6587 views 14 times favorited 18 comments Add to Favorites Watch

Sorry it took so long to get this online but my tablet crashed as I was almost done with the posting. GRRRRRR.

This is something I created out of necessity and the fact it was super cool.

This case took over a month to build working on it a little at a time but still would not have been a weekend project. I first had to make a jig to be able to cut the top and bottom faces as well as aid in the assembly process. It took the better part of a day to figure out and build the jig.

The case is made out of Luan 1/4” plywood and the shape was made using a trim router and the jig as the template. The jig was made using a circular saw and a straight edge guide.

All pieces were cut then clamped to the jig except the top face I then glued and pin nailed the parts together. When it was dry I pulled it out of the jig and added reinforcing blocks at all the joint locations. I then cut the top pieces and glued and nailed it on and clamped to dry. I then finished it with Watco cherry colored Danish Oil over the top of some trans tint dye to get the coloring effect that I wanted.

I preceded to do the tedious and meticulous trim work. The trim is actually Poplar that I planed from 1/4” to 1/8” and cut into strips after staining them a Dark Walnut color. I then hand cut and fitted a ton of pieces starting on the sides and finishing with the top. I used a mini Miter box with a flush cut saw to do this. (By the way not having any right angles this will drive you nuts. I suggest lots of beer and good old Rock and Roll) Once I got a few pieces cut I would glue and Pin nail them as I went along.

When everything was dry I stood it up on end and used a HVLP spray to put about 9 coats of semi gloss Lacquer on it. (Lacquer dries faster and I have little patience , but poly would be more durable) I wet sanded the case and put a light coat of clear wax.

This next part required the help of my buddy Jimmy. We built a tall fence extension in order to clamp the case to which would allow the case and fence to slide along the table saw fence like a vertical sled, thus preventing kickback and booboo’s to the wood. I used a thin Kerf 3/32” Freud Blade to cut this apart. (Freud you can send me a couple blades for the plug. LOL) As we cut a side we then inserted 1?8” shims to prevent pinching of the blade and taped them to prevent movement.

Once it was apart I was able to finish the interior and clear coat it. I also added some more luan strips to the sides for structural support of the handle hinges and locks. Next I cut the Kaiser foam to fit. (DO not glue in yet, it is easier to fit before the hinges are installed.)

I then put the lid back on the case and lined it up and clamped it to prevent moving. At this point I installed all the hardware. (the hinges have a 90 degree stop so there was no need for a lid stay.) I unclamped everything and checked the fit. Next I glued in the lid piece of foam and the bottom piece in the case. I left the thicker piece in the bottom case loose so it can be removed and another piece cut for a different configuration.

Total cost of project just under $300.00 and LOTS AND LOTS of cold beer.

I cant wait to see the looks on peoples faces when I take it to the range.

-- Failure is always an option. :-)

18 comments so far

View GeneR's profile


151 posts in 2420 days

#1 posted 09-08-2013 09:48 PM

The foam is not cut in the picture because it is currently for sale, And I used Kaiser foam because it is designed for tool storage and will not wick oil away from the tools.

-- Failure is always an option. :-)

View lew's profile


12841 posts in 4237 days

#2 posted 09-08-2013 11:01 PM

Like the case AND what’s in it.

-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View TopamaxSurvivor's profile


18658 posts in 4158 days

#3 posted 09-08-2013 11:02 PM

That should pop a few eyes out! Awesome case. Where do you find Kaiser foam?

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View whitebeast88's profile


4128 posts in 2672 days

#4 posted 09-08-2013 11:33 PM

sweet case!!!

-- Marty.Athens,AL

View dpwalker's profile


273 posts in 3313 days

#5 posted 09-08-2013 11:35 PM

VERY nice case. It should raise some eyebrows.

-- You have not really lived until you do something for someone who can never repay you.

View GeneR's profile


151 posts in 2420 days

#6 posted 09-09-2013 01:11 AM

You can get the foam trough rockler. I was going to us pick apart foam but it sucks up oil and water not to mention it was going to be around $160.00 for that type of foam.

-- Failure is always an option. :-)

View HillbillyShooter's profile


5811 posts in 2774 days

#7 posted 09-09-2013 01:18 AM

Great case—unusual, but definitely eye catching and one of a kind (until you build the next one). also, thanks for the information on Kaiser foam.

-- John C. -- "Firearms are second only to the Constitution in importance; they are the peoples' liberty's teeth." George Washington

View TopamaxSurvivor's profile


18658 posts in 4158 days

#8 posted 09-09-2013 01:34 AM

Thanks. When I goggled it, not much showed up.

-- Bob in WW ~ "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence

View hoss12992's profile


4149 posts in 2375 days

#9 posted 09-09-2013 07:30 AM

Great job and love the design

-- The Old Rednek Workshop

View natenaaron's profile


442 posts in 2279 days

#10 posted 09-09-2013 04:41 PM

I am sure one trip to the range will it as well as cause orders for more. Interesting and well executed case.

View moke's profile


1413 posts in 3258 days

#11 posted 09-09-2013 05:39 PM

That is cool!! It is so nice I would hate to take it to the range…..but I would love to have it around the house.

-- Mike

View Surfside's profile


3389 posts in 2655 days

#12 posted 09-09-2013 09:21 PM

The wood and finish look incredible. Stunning execution. I appreciate your attention to details. You outdid yourself today!

-- "someone has to be wounded for others to be saved, someone has to sacrifice for others to feel happiness, someone has to die so others could live"

View NormG's profile


6441 posts in 3486 days

#13 posted 09-10-2013 04:10 AM

Very impressive in deed, great case and the weapon to match

-- Norman - I never never make a mistake, I just change the design.

View robscastle's profile


6308 posts in 2686 days

#14 posted 09-10-2013 07:57 AM

Nice job on the case.
What is the weapon it looks like a Colt I used to have in my ARMY commando days!

-- Regards Rob

View GeneR's profile


151 posts in 2420 days

#15 posted 09-10-2013 12:14 PM

Rob it is completely a custom build- lower is high standard (by stag arms), cirro forge upper, military surplus barreldesigned for a full auto, but the gun is not only semi, rock river chromium bcg. Burris optics and a few other goodies I will sell it with the case for the right price. :-) very accurate shoots a large silver dollar pattern at 26 yards with the red dot.

-- Failure is always an option. :-)

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