Flight Case

Construction | Hardware | External | Internal

To enable Packhorse to lead the field in the construction of flight cases capable of withstanding the toughest of environments and the rigours of constant use resulted in new and improved designs in case construction.

The most important downfall of most flight cases is the inherent weakness of pining the case panels together and then riveting an external 'finishing' aluminium edge to the case to cover the nails and plywood joints.

Inherent Weakness:
1. When the rivets are 'set' they only pull into the soft wood on the inside of the case.
2. Case flexing will break glue joint
3. A side impact can 'push in' the panel
4. Aluminium quality is usually too soft

To overcome these problems Packhorse developed a brand new method of flight case construction, by making the aluminium section an integral part of the case construction (yes Packhorse were the first!). This method offered a more rigid case, with joints that could not work loose over time. This in turn produced a far superior case, with increased strength, longer working life, and no increase in weight.

CAD Drawing of Sound Console Case
Designing our own aluminium extrusions to make this possible, a 'double' angle extrusion was produced from high quality hardened alloy (as used in aircraft construction) which was used to join and strengthen the flight case panels.

4 Unit Rack Case with Recessed Fittings

With this method the panels are slotted into the extrusion, eliminating the problem of the glue line breaking, and then riveted in to place. The rivet passes through external angle, the wood panel and the inside angle so when 'set' the rivet pulls the extrusion tight onto the wood.

This 'double' extrusion also adds rigidity to the panels and does not allow a panel to be 'pushed in'.

The next new construction feature Packhorse developed was the use of 'male & female' aluminium closing extrusions. Again made from the same high quality aluminium as the angle, this not only added more rigidity to the panel but ensured that the lid closes securely on the base of the case.

This unique method of flight case construction set the standard in flight case strength and reliability. In fact, today a few other case companies have chosen to follow this superior case technology, but never reaching the Packhorse quality

Packhorse now has a large range of these extrusions to cater for all types of cases Packhorse Flight Cases   .... raising the standards.