Measure the dimensions of the piece of equipment you are making a Canadian road case for. Be sure to take into account any handles, casters or other pieces that are not part of the main structure of the equipment. Add 1 1/2 inches to each measurement for padding, to determine the dimensions of the case.
Transfer the measurements to the 1/2-inch plywood -- using a tape measure and marker -- and cut them out with a circular saw.
Dry-fit the sections of the case together, leave the top off to the side. Once you are sure that the box is the correct dimensions, secure the bottom to the sides with wood glue. Use a cordless drill to drive wood screws through the base of each side and into the bottom of the case. Secure screws every 3 inches.
Measure pieces of black ABS plastic laminate to fit on each of the exterior sides of the case, including the top. Cut the pieces with a utility knife.
Apply the laminate to each side of the box, as well as the top, with spray adhesive. Roll the laminate with a rolling pin, to remove any bubbles that get stuck beneath the laminate during application.
Measure aluminum edging pieces to cover the entire length of each edge of the box. Cut these with a jigsaw.
Attach the edging to the box with 5/8-inch anodized rivets, using a riveting tool. The rivets should be placed on both sides of the edging, every 2 inches.
Screw the piano hinge to the interior of the road case, at the top of the back side, using the screws that come with the hinge.
Screw the other side of the piano hinge to the interior of the back side of the lid.
Attach the heavy-duty aluminum ball corners to each outside corner of the case, using rivets and the rivet tool.
Attach aluminum corner clamps to the top of the box corners and the bottom of the lid corners, with rivets and the rivet tool.
Install the twist-catch locking assembly to the center of the front of the lid and the top center of the box. Rivet them in place through the pre-drilled screw holes.
Attach spring loaded handles to the case, with rivets. For a small case that can be handled by one person, a single handle can be placed in the center of the front panel of the case. For a larger case, a handle can be placed on both sides of the case to allow two people to carry it -- one on each end.
Measure and cut compression foam padding to fit on all six interior sides of the case. Cut two pieces for each side for a total of 12 pieces.
Install a layer of foam padding to the interior of the case using spray adhesive.
Dry-fit the piece of equipment the case will be used for into the padded case. Note the areas that need to be cut to fit the equipment securely -- such as handles, knobs, casters -- and then remove the equipment.
Dry-fit the second layer of foam padding, and cut out the necessary areas with a utility knife. Use spray adhesive to secure the second layer of foam in place.
Close the lid, and check that the locking mechanism works and the handles are secure.