building a case.. from scratch

[doug91]

I have finally decided to start an endeavor on build a complete custom case. I am not new to PCs, I have built my own and know PC hardware forward and back. I am however, a complete noob with case modding.
I was thinking of using Square Alluminum rods and fashioning a fram out of them. For the top, bottom and the two sides I wanted to put plexiglass. Then for the front and back I'd use alluminum sheets and mesh. Is this idea feasible?

ps: i'm not worrying about the innards of the case yet.

[weazel6265]

Thats similar to what I am currently doing. My case is entirely plexi, and I am making it as small as possible. Here are two links that I looked at when planning mine

http://www.tux.org/~bball/pcmods/
http://www.overclockersclub.com/guides/plexicomputercasehowto/

and of course, I have to direct you to my very own worklog:
http://www.thebestcasescenario.com/forum/showthread.php?t=12122

Hope you get some ideas

[doug91]

Nice case man. Thanks for the ideas. Unfortunately, being a gamer with top of the line parts, a small case won't do :( I need a case sticking more to a mid-tower design. A small case like yours wouldn't afford much air flow for my heat monster 8800GT. Was the bondo stuff hard to use?
Also, does anyone have experience with mesh? I want to make the front panel mostly mesh for airflow. I am having trouble figuring out how to screw/fasten/ glue the mesh on.

[weazel6265]

??? I didn't use bondo at all. From what I have heard, it is easy to work with, but I don't know.
And the nice thing about scratch building a case it that you can make it as big or as small as you want. I wasn't suggesting you copy my case exactly, just look for ideas, especially about working with plexi, and then design your own.

What I thought about before I made mine was attempting to use an old beige case, and just cut all the corners out, using them as the frame for all the plexi. Something to thing about if you have tools, but don't want to work with aluminum rods for a frame.

[doug91]

I was just asking about bondo in general. Your mod did give me a better idea of my project design. I gotta give you props for lack of tools used. What I meant by size is that my case is going to be more like a standard mid-tower. I have all the tools of a woodshop at my disposal.
I decided metal was to hard to work with. So I am making a frame out of wood. Then I will put Plexi in for the sides. For the circular fan holes, if my fan is 120mm do I just make a 120mm diameter hole? Also how big did you make the holes for the optical drive?