Extrusions

Aluminium Extrusions for DIY Road and Flight Cases

If you're planning to build your own road case, choosing the right aluminium extrusions is one of the most important decisions you'll make. These components form the structural framework of your case, providing strength, alignment, and protection. At Armor Road Cases, we supply a full range of premium-grade extrusions designed specifically for DIY builders who want to create professional-quality cases at a fraction of the cost of custom builds.

Our extrusions are ideal for musicians, AV technicians, touring professionals, and hobbyists who are confident with power tools and want to take control of their own case construction. Whether you're building a lightweight flight case or a heavy-duty ATA-style road case, our extrusions are engineered to deliver durability, precision, and a clean, professional finish.

We offer one of the most complete selections of road case extrusions in Australia. Our range includes single angle extrusions for basic edge protection, double angle extrusions for joining panels at corners, and U-cap extrusions for finishing lid and base edges. We also stock edge extrusions for panel reinforcement and tongue & groove extrusions that ensure perfect lid-to-base alignment.

Most of our extrusion profiles are available in 3.0M lengths and are compatible with the most common panel thicknesses used in road case construction—9.7MM, 10.7MM, and 18.2MM laminated WBP birch plywood, as well as 7MM PP flight panels. This makes it easy to match the right extrusion to your case design, whether you're building from scratch or modifying an existing case.

What truly sets Armor Road Cases apart is our commitment to quality. While many suppliers offer extrusions made from 1.2MM or 1.5MM aluminium, we stock only 2.0MM thick extrusions. This added thickness provides significantly greater structural strength, better resistance to impact and wear, and a longer lifespan for your case. These are the same extrusions we use in our own professionally manufactured cases, so you can be confident that your DIY build will meet the same high standards.

Planning your build and ordering the right quantity of extrusions is easy with the help of a free tool called OptiCutter Linear. We’ve written a full guide on how to use this tool in our blog: Work Out Quantity of Extrusions to Order for DIY Road Cases.

Our extrusions are perfect for a wide range of DIY case projects. Whether you're building a custom guitar amp case, a rack mount case, a drawer system, or a flight case for lighting or AV gear, we have the right profiles to support your design. Our extrusions are also fully compatible with our range of road case hardware, including ball corners, latches, handles, lid stays, and rack strips—making Armor your one-stop shop for all DIY road case components.

We ship Australia-wide, so whether you're in Sydney, Melbourne, Brisbane, or a regional area, you can count on fast, reliable delivery. Our team is also here to help if you need advice on choosing the right extrusion profiles or calculating how much material to order.

Ready to get started? Browse our full range of aluminium extrusions and place your order today. With Armor Road Cases, you’ll get the quality, support, and materials you need to build a case that’s strong, stylish, and built to last.