It seems the Picture Counting Nazis are out in full force tonight. Thus the Rest of the post.
The locking mechanism from the inside. Next picture shows what it latches to.
I mentioned before that I screwed up the direction I put one of the hinges on. This actually makes it so the hinge gets jammed in position when the box is this far open. This is an intentional.
Also, I used spray on adhesive to keep the rubber gasket in place. That did not work (see picture)
What my hand is holding in place is a 1 inch by 1 inch aluminum L bracket of 1/16" thick. The lock above will move down and Swivel into place locking the thing. I'm going to take my time mounting that L bracket, because I want it to compress the rubber gasket slightly so it will be waterproof(ish), but not too much as to not bend stuff.
The hinge as seen from the inside. The hinges are on axis (somewhat) with that loop there.
The stuff I took off the cases. Approximately 4 lbs of weight savings or 4*2 lbs of weight savings for two. That is about a 20% weight reduction.
I have some more work to do on them, but I think it is coming along quite well. As dubla did, I will spray the exterior with bed liner, and the interior with undercoating. It'll get a rubbery texture on the inside and a tough cover on the outside.
I plan on putting some sort of handle on em. Not sure what type yet. I bought some el-cheapo drawer handles from lowes, but I have questions about their durability. I might get aluminum handles from McMaster for a few bucks.
So the question, is anyone interested in a video tutorial as I make the second one? If you are interested...there is a lot of grinding involved.