Thanks for the comments guys.

The flight box will be painted bright yellow because I already have the paint and I wan't it to stand out so I don't trip over it. All pictures are taken with my wife's new Fuji FinePix S5000 digital camera which I bought her for Christmas - good planning on my part. The 12mm ply will make the box heavier (but also stronger) then the average commercial flight box. As tempting as fold out panels and clear poly paint are, they would constitute a greater complexity then I am equipped for. I'm not a cabinet maker by trade and have to make do with a jig-saw for cutting the wood.

Now back to construction. The first picture below shows the 6mm side panels and 3mm end panel clamped into place to check the fit. the left hand compartment will house the battery and power panel and the right hand platform will support a 5 litre fuel container. After taking the photo, I shortened the battery/power panel compartment to a more practical size. It will comfortably fit an 18 Amp Hour 12 Volt SLA battery but I will be using a 7.2 Amp Hour battery - after all I'm only starting a 46 size trainer.

The second photo shows the smaller of the two drawers. It is made from 6mm ply sides and a 3mm ply base. Pieces are glued and nailed together using standard white glue (no need to use expensive CA glue on a flight box) and 1mm diameter by 10mm long nails. I partially pre-drill the nail holes to prevent the wood from splitting and knock the nail heads below the surface of the wood with a centre punch. The drawer is really strong and will stand up to plenty of rough handling.

If you click on the pictures it will open a larger image.