Sax Case

After high school graduation, Elyse purchased a beautiful old Whitehall professional bari sax. The sax was in great shape, but the case was starting to fall apart. It was simply beat up and worn out.

For a large instrument such as a Baritone Saxophone, the case is important for protection of the uinsturument and maintaining its alignment. We decided to make a new case.

Many of the construction techniques are basically the same as we used for building the boat. A simple form was created to do the bent lamination for thse sides. Scrap plywood sheets were used for the faces and 2x2s were used for the form segments. The sides were made of 3 layers of 1/8" plywood. The plywood was simply screwed down to the form to hold it in place while the epoxy cured.  

The top and bottom are 6mm Okoume plywood. The case is coverd in 4 oz fiberglass with an extra layer of 6 oz glass at the corners.

The fiberglass was sanded and filled until smooth.

The interior is fited with mulitple pieces of wood, high density foam and normal upholstery foam. All coverd with black velour. The original case was used as a pattern for the support points. The hinged "parts box" was a new addition to hold mounthpieces, rreds and other accessories.

For the paint. we had decided on using Imron (which we had usedon the boat). When we went to the paint store, Elyse picked out Fuschia (darn near Barbie Hot Pink). The primer is 3 coats of Nason 2 part high fill polyurethane (really nice stuff to work with). The final finish is 4 coats of Imron. The finish was left as sprayed and not further rubbed out.

The wear strips on the back are UHMW, so that she can drag it up strairs without damage.

Wheels are also provided to ease transport. There are 2 handles, one for carrying, and one for towing on the wheels

The case ended up weighing only 3 lbs than the original of plywood and vinyl!

A shot of the interior with the corner gussets in place.
Exterior sanded with the corners rounded over prior to the fiberglass.
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Copyright 2007 Mark Bronkalla