Building a case from stratch! HELP FIRST TIMER!

[metomeya]

Okay I want to build a case from scratch (cause I couldn't find any cases that has all the features I want:



a MicroATX that has

2 Internal spaces for hard drives

space for 2 or 1 DVD/CD players

3.5" external space (for memory card input (sony cards, etc.)

And USB NOT at the bottom like most cases (makes it really hard to reach all the way to the ground to put it in) but at the top, or upper middle.

And finally handles, four on the front top, back top, bottom front, and back bottom (like this http://www.macorama.net/aua_g5.jpg )



And finally I plan on putting the DVD and CD player vertical instead of hortizonal.









So I'm trying to figure out exactly what I'm going to need to build it. I've went to Lowes, and the Alumium sheet metal is about $16.98 for about a 24" by 18" sheet, and they have these corner "L" spaced pieces for about $2.98 a piece about 20-24" inches long.





So I'm wondering:



1.) What types of tool do I need?



2.) Also what kind of glues are best for metal to metal



3.) Are there speical screws I should use? Like self-drilling?, also if the point is sticking out too far, is there a tool to be able to cut it and able to get into the smaller parts of the case?



4.) Are there any good websites giving a walk-through on doing such a thing?







Welding is out of the questions sine I have no acces too one, and I don't know how to do it. Thanks guys.

[onelegout]

I dont know about glueing it together...
I would drill holes and rivit it together, or just screw it, but ive never held a drill in my life, so dont trust my advice! lol
Peace
H

[Crimson Sky]

A good start for learning how to make a PC from scratch is to get my book (http://www.amazon.com/gp/product/0789731924/002-4518937-6047262?v=glance&n=283155&s=books&v=glance&tagActionCode=thebestcase06-20) :D It has all the info you need to get started, without all the searching online for info.

All the parts for this project were bought at Lowes and Home Depot, and built mostly with basic hand tools. Here is the scratchbuilt mod (http://www.thebestcasescenario.com/index.php?module=photoshare&func=showimages&fid=5) i did for the book.

[Greddy]

Ok there was one tool to teach them... one tool to beat them... one tool to fool them all...
And one tool.... to rule them all...
All of these tools however are the same tool.... Dremel :) cant go wrong ;)
<[G-reddy]>

[Malatory]

Ok there was one tool to teach them... one tool to beat them... one tool to fool them all...
And one tool.... to rule them all...
All of these tools however are the same tool.... Dremel :) cant go wrong ;)
<[G-reddy]>

Dremel is a nice tool but when it comes to cutting large pieces or even cutting a window in a case. there are tools that work faster and leave a nice edge.

but for starting off the Dremel is the way to go.

[Ozzhedian]

You can use a special epoxy to glue the bits together.
Many cars including the Lotus Elise and any Aston Martin since the Vanquish have extruded aluminium chassis' which are glued together and they are believe it or not sustantially stronger than welding the chassis together. It should be easier too, so long as you can find the right epoxy. Not too pretty though.
And i would recommend Paul's book too. I have it and it's killa. Its like having this forum between 2 covers.
Jigsaws and hole saw bits for your drill always come in handy. If you plan to have presision cuts made professionally, then laser cutting wont help you, because the laser 'burns' aluminium. Someone with a CNC would be able to sort you out just fine though.
Cheers.
Oz

[Forvak]

For joining two pieces of metal together you should look at jbweld (http://jbweld.net/products/jbweld.php). It is as strong as steel and is easy to work with.