A lot of people keep asking me at conventions, where I got the box I use for my fursuit, since they look for something sturdy which will survive any rough handling you may see (or not see) at airports. Since my box is a custom build and I ended up answering the same questions all over again, I decided to write a little tutorial here.

At this point I want to give full credit to  qetesh who came up with the original idea!

To answer the most common questions in advance: The empty weight of the case is 11 kilos and has an dimension sum of a little under 153cm, so it does count as normal check-in luggage, although airlines will mostly ask you bring it to the oversize baggage counter. You won't have to pay any additional fees though.

Material list
To get started, here is a list of materials you will need for this build. I will link to the primary sources where I got it from, but you should be able to find different ones.

- Thon Accessory Case 60x40x40 BR
- 2x Adam Hall 3782 Edge Castor 40mm
- 2x Adam Hall 4982 Plastic Foot 85x33x43mm
- Adam Hall 34704 2-stage pull out handle

This covers the primary build. Additionally, you will need the following list of screws, nuts and washers (you might use different ones, but these are the ones I used):

- 4x ISO 7380-1 A2 M5 x 22mm (for the back of the edge castors)
- 2x ISO 7380-1 A2 M5 x 18mm (for the bottom of the edge castors)
- 4x ISO 7380-1 A2 M5 x 25mm (for the pull out handle)
- 4x ISO 7380-1 A2 M4 x 18mm (for the feet)
- 34x ISO 7089 A2 200 HV M5
- 10x ISO 7098 A2 200 HV M5
- 4x ISO 7098 A2 200 HV M4
- 10x DIN 985 M5
- 4x DIN 985 M4

The basic build will leave you with a lot of screw heads and rivets on the inside of the case. Qetesh originally just covered that up with a bed sheet, but I wanted to go for something more professional. So I got large sheet of cellular rubber (1mm thick) and attached pieces to the walls and ceilings with double sided tape. As I wanted to be able to easily remove the cellular rubber when I needed to reach to screws to replace one of the parts, I used self-adhesive velcro to attach the rubber to the floor and the back side where the castors are attached.

You can find a PDF with all measurements for the rubber here: https://sta.sh/010dv7nhkmjo

The actual build
So, now that you got all the materials, we can get started! Here you can find an album containing all pictures you might need for illustration:

https://photos.google.com/share/AF1.....12OTdnTV9RbERn

First thing you want to do is to position the feet, the castors and the handle on the places you want them to be. You then mark the holes with a pencil and get your drill. Drill 4mm holes for the feet and 5mm holes for the castors and the handle. Make sure to do this slowly, as otherwise you might damage top layer of the wood.

Then start attaching the items with the screws. Always place one large washer on the inside and one or two of the smaller washers on the outside. For the back of the castors, I actually placed two small washers on the inside on top of the large washer, as the screw was just slightly too long (I wanted to have the nut on the back flat with the plastic). You might have to experiment a little to get everything aligned nicely, but for the screws on the bottom of the case it is not too important.

Now when all elements are attached, you should vacuum the inside before going on to the next step. Now cut the cellular rubber into pieces as shown in the PDF. Use velcro on the sides where you placed the screws, so you can easily remove the rubber there when you need to replace the castors or the feet. For the other sides you can just use double-sided table. As a final touch, you can use small pieces of rubber to cover the area around the locks.

So, that's it, now you have a fully functional transport case for your fursuit, which is pretty much unbreakable! I'd love to hear about your experience with this!