Thank you - you may want to look at foam core - Euclid440 suggested it and I picked up a sheet from a craft store. It really allowed me to play with the design until I figured out the look I wanted. It's pretty cool stuff and could have easily been covered with material and used in the final product. I had some scrap maple laying around so I wanted to make use of that. Otherwise, I think I wold have just covered the foam core and called it a day. Would have given me a tight fit and I may do that for a travel box.
Adam