DF95 Transport Box — Fully Assembled & Ready to Sail

Flat low-profile case · boat laid on port side · top panel is the lid · 1:1 scale diagrams

Basis: Official Joysway DragonFlite 95 specifications
Hull LOA: 950mm · Hull beam: 125mm · Overall height (keel tip to mast tip, fully rigged): 1470mm · Rig height above deck: 1050mm · Weight: ~2000g
Keel draft ~280mm + hull depth ~140mm + mast above deck 1050mm = 1470mm ✓
Orientation: Boat lays on its port side, fully assembled and rigged. The 1470mm mast-to-keel span runs along the box length. The 950mm hull bow-to-stern runs along the box width. Hull beam (125mm) is the box height. Jib boom extends ~90mm beyond the bow, setting the box width. Sails remain fully rigged — never folded or rolled. When the boat lies on its side, sails spread flat in the same plane as the starboard hull face (facing up). They lie within the mast/boom/jib boom footprint already defining the box plan area, and add no height to the box.
¼″ birch ply — sides and bottom
¼″ polycarbonate — lid (clear)
1″ closed-cell foam lining
Piano hinge — lid rear long edge
1×1″ aluminum angle corners
Pipe-foam cradles (hull & mast)
Latches, handles, hardware
Interactive 3D View — Drag to Rotate · Scroll to Zoom · Open / Close Lid
DF95 Transport Box
1620 × 1190 × 240 mm exterior
━ Piano hinge — stern long edge
▪ Polycarbonate lid (clear)
Drag · rotate
Scroll · zoom
Isometric Views — Closed (left) · Open, Boat Loading (right)
POLYCARBONATE — CLEAR 1620 mm 240 mm 1190 mm Piano hinge — full 1620mm length (stern edge) Draw latches ×3 (bow/free edge) LID CLOSED hull keel mast gas strut Piano hinge (open) keel bulb mast channel LID OPEN — Loading
End Cross-Section — Looking In From Keel End (shows 1190mm width × 240mm height)
LID ¼″ polycarbonate (clear) hull — 950mm wide · 125mm beam (here = vertical) keel fin + bulb (into page) mast (into page) 1190 mm exterior width 1128mm interior (hull 950mm + jib 90mm + foam) 240 mm 125mm beam ← stern side bow/jib side → (keel and mast both run into the page along box length)
Gas Strut Detail — Connection Points & Placement Along Box Length
End Cross-Section — Gas Strut Geometry (schematic) lid — closed (dashed) piano hinge lid open ~70° (continues to free edge) Box-side mount: 60mm below hinge, stern wall interior face Lid-side mount (open): 300mm from hinge along lid underside Lid-side mount (closed) Extended ~350mm (lid open) Compressed ~300mm (lid closed) 1190 mm interior width ← stern (hinge) bow (latches) → 240 mm Strut Positions — Plan View (lid removed) piano hinge — full 1620mm length bow wall — draw latches Box-side mount ● Lid-side mount ○ 400 mm 400 mm 820 mm between struts ← keel end mast end → Box-side mount (stern wall interior) Lid-side mount (lid underside, 300mm from hinge) Strut spec: compressed ~300mm, extended ~350mm (~50mm stroke) e.g. Stabilus BLOC-O-LIFT or equiv. 20–30N · order matched pair
Top-Down Plan View — Lid Open, Looking Into Box (fully assembled DF95 · uniform scale)
LID OPEN — 1620 × 1190mm · ⅜″ ply · swings up from hinge line below ↓ gas struts hold lid at 90° gas strut gas strut ⑤ PIANO HINGE — full 1620mm length, lid rear edge (hinge line) ← keel end mast end → stern side bow / jib side keel bulb keel channel keel zone · 280mm draft stern bow 140mm depth hull 950mm mast — 1050mm above deck + hull mast tip 1050mm mast span inside box main boom 535mm gooseneck jib boom 480mm (aft along deck) clew mainsail — fully rigged, lies flat jib — fully rigged, lies flat strap① strap② ③ draw latches ×3 — front long edge (bow side) 1620 mm exterior length (mast–keel direction) 1558 mm interior (1470mm boat + 44mm clearance each end) 1190 mm exterior width (hull direction) hull (port face up · lying on starboard · 125mm beam) mast in pipe-foam cradle channel keel bulb in foam pocket pipe-foam saddle 44mm 44mm

Box Exterior Dimensions

Length: 1620 mm (63.8″)
Width: 1190 mm (46.9″)
Height: 240 mm (9.5″)

Interior Clearances

Mast+keel 1470mm → 44mm each end
Hull+jib 1040mm → 44mm each side
Beam 125mm + 50mm boom clearance

Estimated Weight

Plywood panels: ~5.5 kg
Al angle + hardware: ~1.5 kg
Foam padding: ~1.0 kg
Empty box: ~8 kg (17.5 lb)

Fits In

Full-size SUV seats down: ✓
Full-size pickup bed: ✓
Mid-size SUV (large): check
Hand cart (30 lb loaded): ✓
Bill of Materials — All Items at Ace Hardware / Lowe's / Home Depot
#PartStandard SpecLightweight Alt (Coroplast panels)QtyEst. CostNotes
PANELS — all from standard 4×8 sheets (2440×1220mm)
①aBottom panel¼″ birch ply, 1620×1190mm6mm Coroplast corrugated plastic, same size — ¼ the weight, waterproof1Ply: ~$50/sheet × 2
Coroplast: ~$30/sheet × 2		Box floor; rubber feet on underside corners. Coroplast takes screws into aluminum angle.
①bLid panel¼″ clear polycarbonate (Lexan), 1620×1190mm — boat visible when closed. Alt: ⅜″ birch ply (~$50) if clear lid not wanted.1Polycarbonate: ~$90–120/sheet. Use backing plates at latch and hinge screw points to prevent cracking.
①cLong walls ×2¼″ ply, 1620×228mm each6mm Coroplast, same size2Ply: included in ①a sheets
Coroplast: included in ①a sheets		Both fit on one sheet side-by-side
①dShort end walls ×2¼″ ply, 1178×228mm each6mm Coroplast, same size2Cut from offcuts of ①a or ①c sheet
FRAME — Aluminum Angle 1×1″ × 1/16″ (same for both panel options)
②aVertical corner anglesCut to 228mm × 4 pcs—4~$28 total (two 8-ft sticks)Box vertical corners; glue + #8 screws
②bBottom perimeterTwo 1620mm + two 1178mm—4 pcsStiffen base edges
②cTop perimeter (lid rest)Two 1620mm + two 1178mm—4 pcsLid rests on these when closed; latch strike plates here
LID HARDWARE (same for both panel options)
③Draw latches ×3Steel draw/toggle latch, 2–3″—3~$7 ea.Evenly spaced on front bow-side long wall; add nylon backing plate behind each screw for PC lid
④Piano hinge1½″ × 72″ steel piano hinge—2~$15 ea.Joined end-to-end for full 1620mm rear long edge; Stanley CD807 or equiv.
⑤Gas struts ×210–12″ gas spring, ~20–30N—2~$18 ea.Hold lid open hands-free at ~1/4 and 3/4 along length; Stabilus or equiv.
HANDLES (same for both panel options)
⑥aEnd handles ×2Recessed flush pull, heavy-duty, rated ≥ 20kg—2~$8 ea.One on each short end wall (keel + mast); main two-person carry points
⑥bSide handles ×4D-ring surface-mount handle, 4–5″, rated ≥ 15kg—4~$7 ea.Two per long side wall (stern + bow), set ~400mm from each end; allows single-person truck-bed/roof lift
FOAM PADDING & CRADLES (same for both panel options)
⑦aFloor/wall/lid foam1″ closed-cell foam sheet, 24×48″—4~$12 ea.Line all 6 interior faces; spray-glued in place
⑦bHull saddle foam2″ foam sheet, 24×48″—1~$18Shaped to hull curve for starboard face; lay on foam floor
⑦cMast/keel cradle¾″ ID pipe insulation, 6-ft length—4~$3 ea.Split lengthwise; channels for mast, keel fin, main boom, jib boom
⑦dSpray adhesive3M Super 77, 16 oz—1~$14Bond all foam to panels
⑦eVelcro hold-down straps1½″ × 18–24″ hook-and-loop—4~$4 ea.2 over hull, 1 over mast, 1 over keel; screw anchors through foam to panel. Do not route straps over sail panels.
FASTENERS & FINISH
—Screws#8 × 1¼″ coarse pan head (for ply)#10 × ¾″ sheet-metal screws (for Coroplast — bite into angle only)~100~$8/boxPanel-to-angle joints; pre-drill
—Rubber feet¾″ adhesive bumpers—8~$4/pack4 on box bottom, 4 on lid outer face
—Wood glueTitebond II, 16 ozConstruction adhesive (Loctite PL) for Coroplast-to-angle bond1~$8Seams
—Exterior varnishSpar varnish, quart — 2 coats outside, 1 insideOmit for Coroplast panels (plastic needs no sealing). Touch up cut edges with edge tape instead.1~$15 (ply) / ~$0 (Coroplast)Seals ply from moisture
Estimated Total — Ply panels + PC lid (recommended) ≈ $260–310 USD  |  saves weight of ⅜″ ply lid; boat visible through lid
Estimated Total — Coroplast panels + PC lid (lightest) ≈ $210–260 USD  |  roughly half the panel weight; ideal if box is carried frequently
Estimated Total — All plywood + ⅜″ ply lid (heaviest / cheapest) ≈ $210–250 USD  |  most durable; no visibility through lid
Key Build Notes
  1. Panel sizing: The bottom (1620×1190mm) fits in one 4×8 sheet. The lid (1620×1190mm) needs its own 4×8 sheet of polycarbonate — order one 4×8 sheet. Long walls (1620×228mm ×2) and short end walls (1178×228mm ×2) share a third sheet (ply or Coroplast). Total sheets: 1 PC + 2 ply (or 1 PC + 2 Coroplast).
  2. Correct orientation: The 1620mm box length runs along the mast-to-keel direction. The 1190mm box width runs along the hull bow-to-stern direction. The box is essentially the boat's upright silhouette tipped on its side. The boat is stored fully assembled and rigged — sails are never folded or rolled. When the boat lies on its starboard side, the sails spread flat in the plane of the port hull face (facing up toward the lid). They lie within the footprint already defined by the mast, main boom, and jib boom, adding no height to the box. The 50mm clearance between the hull surface and lid foam prevents the lid from pressing on sail material. Do not route Velcro hold-down straps over sail panels. Note: the mainsail leech roach (curved trailing edge) extends slightly toward the stern — verify that the 44mm stern-side clearance is sufficient for your specific sail cut before finalising box dimensions.
  3. Lid — polycarbonate (recommended): ¼″ (6mm) clear polycarbonate (sold as Lexan or Makrolon at Home Depot/Lowe's) spans 1620mm with moderate flex when unlatched — acceptable for a boat box. Use nylon or aluminium backing plates (25×25mm) at every screw point (hinges, latches, gas strut brackets) to distribute load and prevent cracking. Polycarbonate scratches more easily than acrylic but won't shatter at stress points. For a stiffer lid, step up to ⅜″ polycarbonate (~$140–170 for a 4×8 sheet) and eliminate flex entirely. If the clear lid isn't needed, ⅜″ birch ply is cheaper and stiffer; omit backing plates.
  4. Hull saddle: The boat's starboard side faces DOWN. Carve the 2″ foam into a gentle cradle matching the hull bilge curve. The keel passes through a channel in the floor foam and rests in a pocket at the keel-end wall.
  5. Mast channel: The mast runs horizontally from the hull toward the mast-end wall. Lay two lengths of split pipe-foam along this channel, one for the mast and one for the main boom alongside it.
  6. Keel pocket: The keel bulb sits in a hollowed recess in the foam at the keel-end wall. The keel fin is only 280mm long in this orientation, easy to cushion with foam.
  7. Piano hinge placement: The hinge goes along the STERN-SIDE long edge (so when you open the lid, it swings away from you as you stand at the bow/jib side). This means the bow-side wall carries the three draw latches.
  8. Assembly sequence: Bottom → end walls → long walls → seal + varnish outside → foam interior → lid hinge → draw latches → gas struts → handles → rubber feet.