Building a Wooden, Six Sided Fly Rod Case
If you don't have lumber that has been surfaced, you'll
need to flatten one face and one edge on a jointer.
After running the board through a planer, cut the board to
width.  1" wide strips should work for most one piece rods
and 1 1/4" wide strips should work with most three section
Using a bandsaw or tablesaw, resaw the strips into two
pieces.  After cutting the strips, plane the strips to 1/4"
A Lee Valley Tools Bird's Mouth Router Bit is used to mill
one edge of the strip.  The opposite edge of the strip is left
at 90*.  The angle produced by the bit forms a tight glue
joint with the adjoining 90* strip edge.
Feather boards are needed for a consistent cut.
After applying glue to the strip edges, the rod case is
wrapped with strapping tape to hold the strips in place until
the glue dries.  The case is trimmed to length with a miter
saw.  The trimmed ends are used to make tracings of the
shapes of the caps on a 3/4" thick piece of wood.  The end
caps are trimmed to size on the bandsaw.
A rabbet is made along the edge of the cap with a
straight bit.  A router bit with a guide bearing will also
Leather straps are used to attach the cap to the case.  The
bottom cap is epoxied in place.