A Suitcase From Jerry Can

It is no matter your profession or your age, this suitcase from a jerrycan will ensure that you travel in style.

How I did it - you can check by looking DIY video or you can follow up instructions below.

For this project you will need:

Materials:

Jerry Can;

Butterfly latch: https://bit.ly/3drZPc1

Rubber Edge Seal 3m: https://goo.gl/ryXLwD

Pair of hinges;

Pop rivets for hinges and latch;

An old suitcase to reclaim a Trolley Folding Handle Mechanism;

M4 bolts and nuts;

5min epoxy (or another fast curing epoxy);

The spray can paint to change internal Jerry Can color (if wanted);

A similar shade of green paint to paint visible edges where metal will be exposed;

Masking tape and few pieces of cardboard;

Tools:

The angle grinder;

File, power file, or another tool to clean burs after the cut.

Drill and bits;

Pop rivets tool;

Screwdriver;

Utility knife;

Clamps and some other usual bits and bobs which is laying around the workshop.

Back in a few years I used a Jerrycan in another project and transformed it into a minibar (How I did that DIY video CLICK HERE). Since that day I kept another idea in my mind which today will see the daylight.

First I covered both jerrycan sides with a piece of the cardboard to protect the surface from scratches along the fabrication process.

Next split the can in half. In the place where the angle grinder wasn’t able to reach - I finished the cut with a rotary tool.

When the cut was done one part still has this pressed metal edge which must be removed.

To clean all sharp edges I used my homemade power file. This is a very useful attachment to the angle grinder which I build recently. Here is the link to full DIY build video CLICK HERE.

To cover all edges I used this rubber edge seal. It is flexible and nicely bends over the corners. I bought it locally, but CLICK HERE to get the equivalent product. Just in case if you want to get it online.

Installation is very simple - just pressed it on the metal edge.

I’m planning to use those small hinges, so marked and drilled holes for rivets. A bit of trimming was needed to get a nice and tight fit.

I fixed the hinges temporarily with bolts and nuts because I will need to disassemble it again. I want to paint it inside when all metalwork will be done.

To keep the suitcase closed and secured I’ll use this butterfly latch. This type of latch is commonly used in heavy-duty music equipment transportation boxes. I’m my case I don’t need much holding power, but it looks cooler than standard latches.

To make marking easier I made a simple template from a piece of cardboard. And the rest part of the job was made by an angle grinder, rotary tool, and a drill.

Since all metal works were completed - it was a perfect time to change the internal suitcase color.

The rest of the open metal edges were covered with a similar shade of green paint. A small detail, but it makes a big difference in the finished item.

Hinges were installed permanently with the pop rivets painted in green. The color wasn't exactly the same tone, but it was quite close.

The butterfly latch was fixed in the same technique. The only difference was that this time I added a washer on the opposite side to achieve more strength.

When all rivets were fixed I reinstalled the rubber edge seal.

I borrowed a Trolley Folding Handle Mechanism from this suitcase.

Removed cardboard protection from the back of a Jerry Can, found the right place for it, marked, drilled, and attached it with few pop rivets.

With the upper part, I needed to disassemble the handle a bit to get access to install the third pop rivet.

Lastly installed the second bottom stand part. Since it has to act as support only a bit of modification was needed.

This cardboard did its job very well, not a single scratch was left.

Ye ye, I’m guessing you all are saying that: “There no way you’ll be able to get in the plain with this suitcase”.And you will probably be right. However, I could use it everywhere else. And what is most important - It definitely pops out from the mass of others.