For those who asked, I will be happy to release a kit just as soon as you send me a laser cutter. But seriously, I will measure up some key dimensions and post them for you. The photo's should be a good enough guide for the rest - just measure up your own flight gear and build the box around it.

Painting away. I gave all surfaces a good sanding followed by a wipe with a slightly damp cloth to prep the surface. Then I applied two initial coats of paint by brush as this lets me work the paint into the wood and seal up the grain and any small gaps. Then another sanding. Then the top two coats were sprayed on (from a can) to give a good surface finish. It may just be the paint fumes but I'm feeling really pleased with my project