I make many, many wooden cases for conductor's batons (think band or orchestra conductors) for a company that makes the batons. In a procuction run I usually make between 25 and 30 at a time. About half are made of walnut and half are purpleheart.
Take a look at my crude sketch below and I think you will get the idea.
Here's the process that I've used thus far:
1. Mill material into 2 5/8" X 18" X 3/4" blanks for top and bottom half of case.
2. Using router with 1/2 spiral bit, route out interior of case top using a jig that the base plate of router follows (velvet covered foam will later be added)
3. Using 2 different templates/jigs route recess in bottom of case for the baton
4. Double stick tape top and bottom of cases together
5. Round over corners and edges of case and sand
6. Apply finish (been using wipe on poly but that is time consuming. Thinking of spraying lacquer with HVLP sprayer)
7. Mask off bottom recesses and apply flocking to baton recesses in bottom of case
8. Attach hinges and latches, install foam padding in top of cases
Any suggestions as to how I can streamline this process? Thanks.
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