How to Choose the Right Gig Bag & Flight Case Size for Your Pedalboard (3D Extents Guide)
Avoid buying a pedalboard case that will not zip shut. Learn how to calculate true 3D rig extents including rubber feet, underside PSUs, tall footswitches, and patch cable plug overhang.
The #1 Mistake When Buying a Pedalboard Case
Every week, guitarists purchase a brand new pedalboard gig bag or heavy-duty ATA flight case, only to discover a heartbreaking reality when packing up for a gig: the zipper will not close, or the lid crushes the knobs on their top-row pedals.
Why does this happen? Most musicians simply measure the bare aluminum frame dimensions (for example, 24" × 12.5"), completely forgetting the real-world three-dimensional elements that expand the total rig volume:
1. Tall Footswitches & Raised Knobs: Enclosures like the Line 6 HX Stomp, Strymon BigSky, or wah/expression pedals extend 50mm to 85mm above the board surface.
2. Side & Top Patch Cable Plugs: Right-angle pancake plugs or straight jacks stick out 10mm to 35mm past the board edges.
3. Rear Rubber Feet & Riser Legs: Elevated slanted frames add 20mm to 70mm of height underneath.
4. Underside Mounted Power Supplies: Brackets and DC bricks add depth below the lower rails.
In this guide, you will learn the exact mathematical formula to calculate your true 3D rig extents and pick the perfect gig bag or flight case the first time.
The 3D Bounding Box Formula
To guarantee your fully wired board fits comfortably with zero strain on connectors or potentiometers, use the 3D Rig Bounding Cage formulas:
📐 3D Rig Bounding Box Formulas:
• Total Width (X) = Board Frame Width + Left Jack Overhang + Right Jack Overhang
• Total Depth (Y) = Board Frame Depth + Top Jack Overhang + Bottom Plug Overhang
• Total Height (Z) = Highest Footswitch / Knob / 2nd Deck + Frame Thickness + Lowest Underside Feet / PSU
Recommended Interior Bag Tolerances
Always add the standard protection margin when comparing your calculated rig extents to manufacturer interior case specs:
Soft Gig Bags vs. Semi-Rigid Hybrids vs. Hard Flight Cases
| Case Type | Impact Protection | Weight | Best For | Typical Interior Depth (Height) |
|---|---|---|---|---|
| Standard Padded Gig Bag | Light (10–15mm foam) | Very Light (1.2–2 kg) | Local bedroom & rehearsal travel | 100mm – 130mm |
| Semi-Rigid Hybrid (e.g. MONO Vertigo / Gator Pro-Go) | Heavy (ABS panels + high-density foam) | Medium (2.5–4 kg) | Regular weekend gigging & van tours | 130mm – 160mm |
| ATA 300 Hard Flight Case | Maximum (Plywood / Aluminum + custom foam) | Heavy (6–12 kg) | International flights & cargo trailer touring | 150mm – 200mm |
Popular Pedalboard Case Sizing Comparison Table
Here is a reference table of the most popular gig bags and tour cases on the market with their verified interior dimensions:
| Case Model | Interior Width | Interior Depth | Interior Height | Compatible Board Setups |
|---|---|---|---|---|
| MONO M80 Club 2.0 | 610 mm (24.0") | 368 mm (14.5") | 127 mm (5.0") | Pedaltrain Classic 2, Novo 24, Temple DUO 24 (Single tier) |
| MONO M80 Tour 2.0 | 813 mm (32.0") | 432 mm (17.0") | 140 mm (5.5") | Pedaltrain Classic PRO, Novo 32, Temple TRIO 28 |
| Gator Pro-Go G-PG-PEDALBOARD | 686 mm (27.0") | 381 mm (15.0") | 152 mm (6.0") | 2-Deck Hinged Boards, Schmidt Array SA450/SA520 |
| Pedaltrain Deluxe Soft Case (Classic 2) | 635 mm (25.0") | 394 mm (15.5") | 152 mm (6.0") | Standard Pedaltrain Classic 2 with tall Strymon pedals |
| RockBoard Flight Case (Cinque 5.3) | 850 mm (33.5") | 450 mm (17.7") | 180 mm (7.1") | Large touring rigs with expression pedals & risers |
5 Golden Rules Before Ordering Your Bag
1. Measure with Cables Plugged In: Never measure pedals unplugged. A solderless right-angle patch cable adds at least 10mm per side; a straight cable adds up to 40mm.
2. Check Hinged 2-Deck and Upper Tier Risers: If your pedalboard has a second deck (like a Schmidt Array or Creation Music Co Aero Riser), your total rig height often exceeds 130mm. Standard budget bags will crush the top deck. Look for cases with at least 150mm interior height.
3. Beware of Expression & Wah Pedals: Wah pedals (like Dunlop Cry Baby or Mission Engineering) sit tilted with a toe-down height of ~75mm. Place wah pedals on the lowest deck slope to save vertical clearance.
4. Inspect Underside Power Bricks: If your power supply protrudes past the bottom rubber feet, it will punch a hole through thin nylon gig bag linings. Ensure your board clearance accommodates the PSU safely.
5. Simulate in 3D First: Use BoardPlannerHub's 3D Rig Studio Inspector to view your exact 3D bounding box wireframe and real-time gig bag recommendations in both millimeters and inches.
Calculate Your Exact Gig Bag Size Instantly
Ready to verify if your rig will fit in a MONO, Gator, or Pedaltrain case?
Open the free BoardPlannerHub 1:1 Scale Pedalboard Planner, build your setup with our 11,900+ verified pedal catalog, and click 3D Rig Studio to inspect your rig's real-time Total Extents (W × D × H) and get instant minimum interior bag dimensions!
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