Custom Touring Pedal Board/Case

for
POD XT Live

Introduction
This case is designed to act as a live setup pedal board and transporting tool. The case is very durable and will last for many years under the worst
conditions. Ive been using cases like this one for years and they have always held up very well. In this case, the pedal board holds the POD XT Live,
a Cry Baby Wah, and a wireless receiver. All of the needed surge protection and power supply devices are contained in the power tray located in
the rear of the case. It is intended that all connections within the cases be semi-permanently installed using various tie downs and clips. This will
minimize setup time and reduce the equipments chances of becoming faulty due to continuous plugging and unplugging of the cables. To setup the
system, simple power up the case, run a cable from the XTL to your amplification system (i.e. amp), and youre ready to go. This design is offered at
no cost to you and I reserve NO exclusive rights to the design whatsoever. Just have fun with it, youre welcome!
About this document
In the following pages you will find (hopefully) all of the necessary information to construct this case exactly as I did. You are free to modify it in
any way you see fit to adapt to your specific needs. If you do, BE SURE to double check your dimensions to reduce material waste and mistakes.
Inside, outlines all of the materials, sizes, source, and cost for all of the needed items to construct the case with finished hardware. There are also
detailed instructions along the way. In the detailed plans section there are mechanical drawings of each part to construct the case along with a
exploded view of the Bottom assembly and the Top assembly to give you a better view of the overall assembly of the parts. BE SURE to review all
of the diagrams and details to get a full understanding of the project BEFORE you begin.
Questions or Help
If you need help, have questions or comments, you can contact me via email at KINGTF@sbcglobal.net
Have fun, enjoy, and Keep Rockin! Oh, by the way, my name is Tadd King, professional musician in Las Vegas, NV. (ex-engineer by trade)

Bill of Materials
QTY
1
1
1
1
25 ft

1
1 qt
100
1 bx
8
2
4
1
10
5
5

ITEM DESC / SIZES

Bulk Materials
2x4x3/4 sheet finishes & sanded plywood
4x4x1/2 sheet finished & sanded plywood
Small box 6d x 1-1/4 finish nails
Tube of heavy duty Liquid Nail
1 wide - Heavy duty 3M Dual Lock or a very
heavy duty Velcro NOTE: Dual Lock is a very
industrial grade Velcro-like material and I would
highly recommend it over velcro
Surge Protector (to fit, max. size 2 x 15)
Good latex based black rust-olium wood paint
1 box #8x1/2 pan head sheet metal screws
Box of assort sized surface mount wiring clips
Hardware
Metal ball cab corners
P/N 260-710
Lift-off hinge
P/N 262-215
Surface mount butterfly latch
P/N 262-350
Surface mount handle
P/N 262-310
Rubber cab feet
P/N 260-771
#10x1 pan head machine screws
#10 thread tee-nuts
TOTAL APPROX. CASE COST
Total finished weight including devices 45 lbs.

SOURCE

APPROX. COST

NOTES

Menards or Home Depot

Menards or Home Depot
Menards or Home Depot
Menards or Home Depot
Menards or Home Depot
Or Web

$10.00
$13.00
$2.50
$1.50
??

Menards or Home Depot

Menards or Home Depot
Menards or Home Depot
Menards or Home Depot

$15.00
$5.00
$2.00
$2.00

For sides and supports (see plans)

For top, bottom, floor (see plans)
For attaching wood pieces together
For attaching wood pieces together
For attaching POD and other devices
to the pedal board NOTE: you could
use Velcro but this stuff is WAY
better if you can find it.
Mounts in the power tray
Semi-gloss, any color you like
For attaching corners, feet, latches
For routing wires inside case

Parts-express.com
Parts-express.com
Parts-express.com
Parts-express.com
Parts-express.com
Menards or Home Depot
Menards or Home Depot

.88 ea / $7.04
$1.35 ea / $2.70
$6.50 ea / $26.00
$4.90
.78 ea / $7.80
.10 ea / $0.50
.10 ea / $0.50
$100.00

Heavy duty steel zinc cab corners

Heavy duty steel zinc hinge
Large heavy latch (no dish)
Heavy duty zinc spring loaded
For bottom and back of case
Attach handle to case
Attach handle to case
Not including Dual Lock

Step-by-Step Instructions
STEP 1:
Layout and cutting the piece parts
Begin by laying out each part on the plywood per the attached drawings using a good square and pencil. Double checking your measurements as you
go along. Total time for this activity is about 3 hrs.
Using the 4x4x1/2 sheet first, carefully layout parts A, G, & H. You should have some scrap but this is necessary because these parts are
so large. Take care when laying out part A (floor panel) to orient it correctly so that the finished side of the wood will face up in the assembly.
Using the 2x4x3/4 sheet, layout the remaining pieces (sides, and supports) parts B, C, D, E, F, I, J, K. Again, please note, that you will need
to orient the irregular shaped side pieces on in your layout depending on the finished side of the wood. In other words, the angled side pieces
should be laid out in a mirrored or opposite each other fashion.
Cut the parts from both sheets using a table saw (preferably). Take special care to cut as precisely as possible, take your time. Also, on the
support parts C & D note the 5 degree angle on the one edge of each part. Dont forget to adjust the saw blade to make this cut appropriately.
The angle is necessary to accommodate the slope of the inner floor.
IMPORTANT to remember, always measure twice and cut once! Or you could end up buying more wood to do it over.
After cutting all of the parts, lightly sand the edges too remove burrs and smooth. Do not over sand or round the edges!
Before proceeding, dry fit all of the parts using the attached exploded drawings and check for fit. Make sure you have the finished side of the
parts facing to the outside of the case. Obviously, if they dont go together correctly, you did something wrong. Correct any errors before going
on. Hopefully you wont have any.
NOTE: The front of the angled floor piece should nestle in the corner between the front panel and the bottom panel, and rest on the
center support and the rear support. See Section View on page 8 for reference.
STEP 2:
Assemble Lower Case
Prepare to assemble the cases. Youll need the Liquid Nails and a caulk gun, finish nails, hammer, nail set punch, and clamps (ideally). Refer to the
detail drawing of the Bottom Assembly exploded view, as you work for reference.
Start by placing the Base Panel Part G on the work table with the finished side down and the long edge facing you.
Attach the lower right side panel Side Panel Part E to the rough side of the Base Panel Part G, aligning the right side edges. Note that the
side is to be on top of the base NOT attached to the side of the base. Use a bead of Liquid Nails on the edge of the Side Panel and clamp it to
the base. Wipe off any access glue with a damp paper towel. Next, flip the assembly over and drive several finish nails thru the bottom of the
assembly into the side for added strength. Set the nails. Note that once the glue is cured (over night) the pieces are permanently joined together.

 Next, assemble the Front Panel-Part F and Back Panel-Part B first. Then the Rear Support-Part C, and Center Support-Part D. Use the
same method as described above.
When installing the Rear Support, glue it in place in the upper right hand corner of the assembly, attaching it to the back, base, and side.
When installing the Center Support, measure in from the very back edge of the case 5 and draw a line. Use the line as a guide to line up the
supports edge. See the Section View on page 8 for reference. BE ABSOLUTELY SURE that the angled edges of BOTH supports are oriented
properly per the Section View. Before nailing, set the Floor Panel in place as shown in the Section View and make sure that the power tray
edges line up properly. Adjust as necessary.
Clamp and nail the parts together from the bottom and sides. Set the nails.
Next, attach the Floor Panel-Part A. Refer to the Section View for proper fit. Glue and nail it in appropriately.
Finally, attach the left Side Panel-Part E in the exact same manner. Clamp all as needed and let it sit for a day to cure the glue.
Assemble the Upper Case
Use the same exact methods to assemble the top of the case. Right side first, then front and back, then left side. Glue, clamp, and nail.
STEP 3:
Paint both cases, inside and out
Using the Rust-Olium paint, proceed to paint the entire assembies with two or three coats. Allow to dry appropriately between coats.
You should now have both halves ready to add hardware. The top case should mate nicely to the bottom case along the edges.
STEP 4:
Assemble Hardware
Hinges Place the TOP on the BOTTOM aligning all edges and clamp the two together to prevent movement. Using the #8 sheet metal screws
attach a hinges evenly along the back edge of the two assemblies. The male side of the hinge should be attached to the top and the female to the
bottom.
Butterfly Latches Assemble two of the latches, evenly spaced, along the front edges of the case, butterfly on the top assembly (see photos).
Assemble the other two latches, one on each side of the case in the same manner along the angle edge of the sides.
Rubber Feet Attach six (6) of the feet to the bottom of the case, two alone each side, and tw down the middle. Use the #8 screws. Attach the
other four (4) feet to the back of the case (the side where the hinges are located). Two on the bottom half in the corner, and two on the top half in
the opposing corners.
Handle Stand the entire case on end with the front facing up. Locate the handle in the center of the front face and mark and drill 5 holes large
enough to accommodate the tee-nuts (~ 3/16 dia. I think). The handle should face down toward bottom half. On the inside of the top case, insert a
tee-nut in each hole and hammer into place. Using the #10 machine screws attach the handle securely to the case.
Corners Attach a metal corner to each of the 8 corners using the #8 sheet metal screws.
STEP 5:
Attach devices to the pedal board and wire it up
Using the Dual Lock, attach all of your devices. Remove the rubber feet from the XTL and replace the screws as they hold down the inner chassis of
the unit. Route patch cables using clips. Attach surge suppressor in tray and route power supplies and wires neatly inside. DONE, ENJOY!!

5 REF