I haven't gotten into building cases myself (yet, anyway...) but I've visited some of the better case builders and seen their techniques.
The plush cloth lining is done by upholstery methods, like making up a cover for a couch. They make up patterns with parts, seams, darts, etc. The parts and seams are all sewn together on sewing machines, on the backside. Most of the plush work is one big sewn-up assembly. The sewn seams are what holds it all together and in the correct shape. But it has to be made right, so that the shape fits the cutouts in the foam. Then they spray the backside of the cloth and the inside of the foam with contact adhesive, and carefully stick the whole thing down in there. The only separate parts are some of the accessory boxes and doors.
It's a lot of skilled labor. I remember the guys at A & S Case Company telling me that installing the plush fabric lining is about half of the labor of building the case.
If you don't want to get into all that yourself, you could always build the case shell and cut out the foam, and then take it to a local upholstery shop to have them sew up and install the cloth. That's exactly what upholstery shops do, and most of them aren't very expensive.
Last edited by Bruce Johnson : 07-31-2013 at 06:25 PM.