Appropriate hardware going to include wheels to roll the loaded cabinet on. and a pull Up handle.?
If I were you I'd mold release finish the box so you could pull the FG shell off of it.
and use the Shell .. weigh less.. still plenty sturdy.. it doesnt have to be as string as a boat ..
+ they will charge you for weight every trip.
Since I am not sure how to go about that I have to stay with what I know. As for weight I can bring it in at about 17-18 lbs.. Which is about what the factory made ones weigh.
That is a pretty cool project. I have thought about doing something similar, but for me I decided against a hard case. Since I pretty much always start and finish my tour is two different cities that are a considerable distance apart it just doesn't work. I will be interested in following your progress though, so please do keep us posted.
Neat project indeed!
Just a word of caution... If you're planning on traveling internationally with this case, do make sure you're using treated wood. To prove this, an uncovered wood area must also have a special ISPM-15 stamp somewhere to demonstrate proper treatment. Many countries have strict guidelines on wood materials entering their borders. It's an ecological protection against agricultural pests. Failing to show this proof, you'll risk your entire shipment being confiscated, quarantined and/or in some countries even destroyed.
Interesting project. I can't see a single wooden box loaded with a tandem making either the airline max weight, or the max dimensions. A tough call. How often will you use the travel case, or cases in the next 10 years? If you only intend to make a couple trips, the extra fees for overweight or oversize luggage are insignificant in the long term.
My personal preference would be to purchase 2 SERFAS cases. You and your stoker can each check in one at the airline. And if you have a scale handy, you can pack your stuff in the boxes, but not exceed the max luggage weight.
The one who has the most bikes wins.