I'd build a wood form with vacuum manifold to the exact internal shape I wanted, designing for clam-shell peripheral symmetry so one form could serve both halves, then have it thermoformed by one of several local fabricators, in PVC, ABS, or polycarbonate sheet. For liner foam I'd contact California Packaging or similar vendor and see what they offer in the way of resilient, closed-cell sheet foam. Hinges, hasps, locks, etc., are off-the-shelf items or obtainable from companies with an Internet presence. Could be pricey for a one-off, for the man-on-the-street or an industry outsider, and the woodworking may not be easily doable for the average hardcase-buyer. But that's what I'd do. ;) PS: If you can break it down sufficiently, a couple of hard rifle or shotgun cases might work fine. __________________________________ Yahoo! FareChase: Search multiple travel sites in one click. http://farechase.yahoo.com