Henry Gun Case Project

[BrokenolMarine]

Back in the shop several times today, finished up the final filling of the small details, then used a Nickel to draw the radius on each corner, after I used the small clamps to clamp the top and bottom of the case together. Carefully cutting a flat on the widest part of the radius, I then sanded the corners to round them off. One final pass over the entire case and ....

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The stain is now soaking in and I'll wipe it down tomorrow. Then I'll wax it and let the wax haze a bit and buff it out by hand.
I'll fit the hinges and latches if I don't think it needs a second coat of wax.
After that, it's time to start on the interior.
The interior will be last, as I wanted to wait so I avoid as much sawdust as possible.

[BrokenolMarine]

Went out this morning and waxed the case. She is looking good. Then I went out to the wood shed and found the hard foam that the boss told me she stuck out there. Measured and marked the foam and ran it thru the bandsaw to get the width correct, than a pass across to get the length right. I ended up with a 5" thick piece that fit.

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The next step was to measure the depth of the top. Meh... 3/4" or so. I marked that on the side of the block of foam and ran 'er through the bandsaw... she fit the top very well.

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I laid the Big Boy Carbine on top of the top, so I could measure the thickness of the rifle, and see how much of a base I would be allowed in the bottom, and how thick the secondary foam would be. Calculations... Bottom needed to be 1/4" and the rest of the thickness would be for the insert for the rifle. The top will come down and secure the Carbine in it's slot when the case is on it's side in "carry" mode.

(Like I'll actually carry it around that much.... )

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Made the appropriate cuts, then checked the fit. Yup, they fit. Outlined the Carbine once I decided where I wanted it. I cut out the slot for the rifle VERY carefully with a razor sharp exacto knife. Miss Tina says she will help cover the foam with the Burgandy Velvet. If I screwed it up, I have plenty of Foam, and can start over. NOTHING will be glued in place until it all fits just so.

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By the way, here is a peek at the waxed box, another couple coats of wax will make 'er glow. I'll have time while Miss Tina works on the velvet

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[RanchRoper]

Classy case for a classy rifle.

[BrokenolMarine]

I have brass piano hinges, brass latches, and a leather trunk handle. Classy, yes?

[BrokenolMarine]

While Tina worked on the inserts I was working on the hardware installation. First up was the Piano Hinge for the rear of the case. Gather the tools. The right tools can make the job so much easier. I used a centering punch, a small brass mallet, cordless drill and pilot bit and a proper screwdriver. Note the magnetic tool tray. It works with the brass "plated" screws.

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I held the hinge in place with a light clamp pressure until it was screwed in place. Careful measurements don't matter if the clamp shifts after the first few screws go in and the hinge ends up crooked.

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Once the hinge was in place on the bottom half of the case, I aligned the top half, clamped that in place, and worked my way from left to right, insuring the hinge stayed aligned from one end to the other. Each screw was snugged. Never want to overtighten the small screws. Shear off a head and you have a tough error to correct.

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Now that the hinge is installed, time to lay out the front.

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Have the latches and the nice leather handle to install. Carefully position each one, then try them for function. Ah... latches will work. Install them.

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Hmmm, testing the nice leather handle... ... it's not going to work. It's too short in length to open up enough. It looks great, but function wise, it's too small for larger hands, and with the weight the case will contain... It's just not going to get the job done. I'll save it and use it has a handle for a nice custom box. I will order a larger more appropriate handle. Should just take a day or three. Give me time to redo the bottom foam. Testing of the foam pads has proven that the lower foam is just a tad too thick. I'll redo that one and leave a little room for the box to close.
Closing is always a good thing.

I stated early on...
... that this was a learning process.

[BrokenolMarine]

I got out this morning and worked on a second try at the bottom of the gun case, and it's foam insert. This time I made sure the foam was JUST a hair below the edge of the rim of the lower half of the case, and rather than try and trim a piece off the bottom of the foam, I cut out the whole outline, then cut a portion of the removed section to pad the back half of the rifle and fitted it back in, then a thicker portion of the barrel section of the rifle and fitted it back. Excellent.

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I cut another section of blue foam, then cut it to width and length and fit it in the bottom, drew around the edge of the rim, and then cut JUST below the line to make it the right height. Rather than use the old piece as a template for cutting out the form for the rifle, I redrew the form after deciding just the right placement. (again... )

I took my time, and tried to make the cuts as smooth as possible. This will make the velvet fit better than if I had just hacked away the foam and hoped for the velvet to cover my half hearted attempts. As you can see, the Big Boy lays in the slot pretty well. Now it's just a matter of getting the Deep Burgandy Velvet to look good laying over the foam insert, to look like someone who had a clue put the package together.

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We are ALMOST there. I'm excited... are you?

[BrokenolMarine]

I edited the photos, the first one looked all crunched up and stubby, so I swapped it out for a proper pic....
It looks better now. Sorry.

BOM

[RanchRoper]

Looks great.

[BrokenolMarine]

Yup! It's Finished!

Worked again this afternoon with the Burgundy Velvet the wife found for me... and the case is lined.

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The Big Boy Carbine 357 fits nicely in it's slot but is flush with the top of the bottom half of the case.

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It's nest is padded underneath to protect the Carbine, and the lid closing down pinches it just enough so it doesn't move. No movement means the Skinner Sights won't get banged up. Yes, it does close right up, and you can "feel" the pressure in the last little bit.

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The only question now is...
"What will I do with it now that I am done?"

I know that I won't actually use it. I don't use cases very often, and I have a couple hard plastic cases and a couple soft cases to bang around if I need them. I certainly wouldn't bang THIS dang thing around... not after all THAT work. I have an idea where it could end up... But... if someone has a great idea ... let me know...

When I look at the case, it turned out much better than I expected, but I still see a few flaws. But I see them in EVERY single project I complete.
Every one. I can't help myself. I know how to avoid them in the next case if I was to build one. But... the results answered my question. Yes, I CAN build one.

A few notes:

The inserts are held in place by pressure and they can be removed if need be. If I decided later to change the case to fit another gun, wanted to replace the Velvet, or needed to make an adjustment or repair...

The finish is Watco Cherry Oil Stain followed by about FOUR coats of BeesWax buffed to a satin shine. If it dulls, you just wax 'er again. Dent it, you repair the dent, add a touch of the Watco Oil Stain to match, and then wax and buff to match. Easy Peasy. I did NOT add the handle after all, since I look at this as more of a presentation case... but the handle COULD still be added. It would be another $30 to $60 to do so. Yup, quality is expensive.

I enjoyed the build, I hope ya'll enjoyed watching. My next build will be the gunsmith's tool chest for my desk. I don't guess ya'll have to watch "everything" I build.

[CT_Shooter]

Awesome! What a beautiful job. Thanks so much for the descriptions, the photos, and the tips and tricks. It's a GREAT contribution.

[BrokenolMarine]

Thanks CT, I have enjoyed sharing, even my "learning opportunities."

[JEBar]

nicely done, nicely done indeed .... questions : do you plan to add a handle ? .... any thought to a glass insert in the lid .... it would make a dandy display case

[BrokenolMarine]

JEBar,

I noted in the very last paragraph that I could add a handle later... but don't plan to right now. The handles I would consider run anywhere from $30 to $60 with shipping. (Leather and Brass) Quality isn't cheap. As for a glass insert... OMG... bite your tongue. I spent hours on end book matching the grain in the top to show it off. If I decided to make a glass top display case, I would make a separate display case for that. I love the interplay of grains and work hard to show them at their best...

I hope folks appreciate the bookmatched top and bottom in this build

[snell]

Amazing, I love to see a true craftsman work. Thanks for sharing the project.

[daytime dave]

That is a beautiful case. A small engraved brass plaque and it would be the presentation case for whatever rifle you had in there.

I really enjoyed reading this thread with it's bountiful photographs and great descriptions. I'm looking forward to the tool chest.

Very nice work.

[BrokenolMarine]

Thank you sir. As you may have seen, the tool chest project is progressing nicely. These things are always somewhat seat of the pants. I decide WHAT I want and start with a rough sketch from measurements. I usually end up thinking about the design over the next day or two and making changes to the design in a final plan drawn to scale. I work pretty much from the drawing, but adapt as problems... ah... challenges... crop up.

The tool chest, as in the gun case, has been no exception.

I just haven't gone into as much detail in my posts with the chest project, not sure of the true level of interest.
I don't mind sharing, as long as there are those who want to watch. I'll be working in the shop anyway, and take the pics for my records of each project.

The boss has told me my very next project...
Will be..
A V-Framed bee hive for the back yard.

[CT_Shooter]

...I just haven't gone into as much detail in my posts with the chest project, not sure of the true level of interest.
I don't mind sharing, as long as there are those who want to watch...

I totally enjoy your woodworking threads and really hope you keep posting them.

The boss has told me my very next project...
Will be...A V-Framed bee hive for the back yard.

I built a top bar hive five years ago using plans designed by P.J. Chandler, the British "Barefoot Beekeeper". Sadly, my hive has been dormant for the last two years after the bees all died from a suspected pesticide (the whole hive was wiped out in just a few days in the early autumn). I decided to try again this year. So far, they're doing great.

This is the first 3 lb package (10,000 Honeybees and a mated queen) that I installed in April of 2012.

Top Bar Beehive and 10,000 bees.

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[BrokenolMarine]

Thanks for the compliment, and the input.

The "Boss" has started reading UP on beekeeping once I told her she would have to BUY bees. She sadly thought that building a hive, it would just fill up. I told her that the way I understood it, without her own Queen, it would be a sad, empty box... she would stare at. The honey bees she sees flying around would return to THEIR queen.

Probably dirt daubers and hornets would move in. One of her online buddies raises bees and told her that once she really decided to do it... she needed to place an order for bees well in advance, and she could get them from HIS source.. very reliable.. not too expensive.. yadda yadda yadda. She told me there was no rush, I could finish my two projects.

This morning she asked me if her HIVE could be the next on the list. No problem, I just like to stay busy. I should finish the tool chest in the next week to ten days and get it on the bench and in use. The box was something she had tried to BUY me for birthdays, Christmas, Father's Day, etc. But I told her I didn't want a knock off cheapo one, and we didn't need to spend the money on a GOOD one.

Doing the Trigger job on the two Snubbies, I decided I wanted to better organize my tools I I wasn't digging thru the four or five LARGE drawers I have the tools in.... The fifteen drawers in the new box will do a good job of organizing everything, plus the bonus chest in the top and the cleaning rod closet.

[RanchRoper]

The Henry case is beautiful. Maybe HRA would buy it from you to use in a promotion or charity prize.

[BrokenolMarine]

I got distracted by the tool chest build, and didn't get back to this until now, when I posted a link to share with a new member. I missed your suggestion RR. It seems great minds think along similar paths. I offered to donate the case to Henry if they were going to donate a carbine to charity, but they said it didn't fit their plans at that time. I still have it, take it out and share it now and then. She still looks good to me.