Tested the DIY road case parts to make sure I understood the process. And I think I do! Thinking I'll get some thicker plywood, though, and route the edges down to fit the extrusion. This is for the Ten Hundred keyboard, all 62"/1575mm of it. That's long enough I think I want at least the bottom side to be more rigid than 1/4" ply will provide.
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I found 1/8" ply worked surprisingly well for a ~20" cube case with the added structure from the aluminum extrusion. I can sit on it and it is stable.
62" is a lot more, but I suspect 1/4" may be plenty between the perpendicular ply preventing bending and the rivets and aluminum preventing twisting.
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