We have all been there. We finish a large model then we realize how in the heck are we going to get this beast to the next meeting or show? I have a solution that is relatively easy to build and is very sturdy. Most models will fit in the Rubbermaid or Safelite lines of plastic boxes. But these larger kits won’t even come close. There are several materials you can use for building a box. One is cardboard and another is insulation foam core. The boxes I have developed are light weight and very sturdy.
All you need is 1×2 boards, mahogany door skin, 1.5″ countersunk screws and .75″ countersunk screws. When measuring the size of the box you will need, add at least 1 inch to all the dimensions to allow for bracing and packing materials. I use simple butt joints on the frame secured with the 1.5″ screws. You have to make sure the screws are all countersunk so they will not interfere with the installation of the skin. Once the frame is built you will notice that it is very strong but light. Then adding the skin does not add hardly any weight. Remember to leave one skin panel removable so you can get at the model. Use an old towel to make cushioning on any supports so the model does not get scratched. Refer to the photos for reference.