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Hard Case for Your Electronic Gadgets

This is my first DIY post in Instructables, so be nice to me!:)

Recently I bought a Zoom H1 handy recorder along with Audio Technica ATR3350 lavalier microphone. From the reviews, I had understood that the build quality of Zoom H1 is not that great and hence I would need a hard shell case to protect it especially while travelling. So, I decided to make one on my own! (As there are no cases which can fit both Zoom H1 and lavalier mic together).

Materials Required

2mm Plywood/ MDF/ Acrylic sheet/Card board/Sun board/ hard Foam sheet (any sheet whichever you find it lying around)
Fevicol Synthetic Rubber based Adhesive
Araldite Epoxy Adhesive
Sand Paper (100 grit)
Hack saw blade with frame
Sponge (Foam sheet)
Magnet (fridge magnet or neodium magnet)
Piece of steel sheet/ coin

First Create a Prototype

You may not realize it, but I think this is a very important step. As you an see I had made this prototype to understand what size would really work well and how it would feel. From this I realized that I prefer placing voice recorder sideways and that I can use a single case to put both Zoom H1 and AT mic together in one case.

Use Scotch tape to join the card board and mount the magnet and the coin. You can use anything you have got; Velcro will also do (I don't like the noise it makes though:))

Measure, Mark and Cut the Sheet

Once you are satisfied with the Prototype, then measure the Plywood sheet. I had fixed on (6"Wx4"Dx2.5"H) dimensions.

I directly used Hack Saw blade to cut the sheet as I did not have access to Hack Saw frame. Make sure you sand the edges once cutting is done to ensure that you won't get hurt while handling it later.

Glue the Rexin Sheet to the Ply

Now, arrange the Plywood pieces together on the backside of the rexin sheet. Make sure you leave a gap for the Plywood pieces to fold later. Use the Synthetic Adhesive to stick it to the Plywood as shown in the images.

Interior Design:)

Now, make a profile to cut on the sponge and start digging using the cutter. Check the depth of cut in-between to make sure that you won't make a through hole by accident.

Finally insert the cut sponge into the box. Cut another slice of sponge and paste it on the inside portion of the top lid for top support.

Final Touches

For fit-and-finish, get a logo cut from any nearby sticker cutting shops (we do have such shops here where they cut PVC stickers for Vehicle License registration plates and decorating cars). For a nominal fee, you can get it cut. You can also use a laser cutting if you have access to it. Personally, I wanted to make a etched metallic laser cut for the logo, but due to inaccessibility to laser cutting machine, I had to settle for silver color sticker.

Hope you enjoyed this DIY! If you like it, just put a comment or say hi:)

Cheers from India,
Sagar Shastry


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