Tutorial on building a case from scratch?

[Trackr]

I have about 5 sheets of 0.8, 0.5 and 1.0mm Aluminium lying around that I'm not using for any particular thing.

I am also in need of a custom cube case that is not exactly to my liking and too expensive.

I don't have a drill press, or a laser cutting station, but I do have a very expensive jigsaw and I've done plenty of modding in the past.

Is there anything to get me started?

 

[Trackr]

Nothing?

 

[staticlag]

Chances are that if you have to ask this question it might be a bit out of your league.

If you want to 100% make the case from scratch and not just modify an existing case...

You're going to need a press brake and a tig welder or else it's going to look play-skool.

You might be able to freehand with the jigsaw but ideally you can measure everything and then take it to a metal shop and have them cut out perfect pieces on their waterjet.

 

[drgnfang]

Chances are you don't actually need any of that...

First - check out any build log by spotswood (such as this one: http://forums.bit-tech.net/showthread.php?t=207663)

Another good build log (with videos & different materials): http://forums.bit-tech.net/showthread.php?t=192623

Also, this series (looks like there's a few more parts to this series under the "guide" section)
http://www.bit-tech.net/modding/guides/2012/04/04/scratchbuilt-pc-part-1-design-and-hardwar/1
http://www.bit-tech.net/modding/guides/2012/04/19/scratchbuilt-pc-part-2/1

 

[Trackr]

My biggest concern is that I will need an angled piece like this:

Because I don't have the ability to weld something so large and thin.

I also don't know of any place nearby that offers a waterjet, but I do know of a place that will happily weld stuff for me.

I suppose I would have to do something like this:

As in, attach a thin of metal to thicker pieces.

I think the point is, is that I am limited to only the sheet metal that I can buy, which would be in.. sheets, large sheets. I don't have the ability to bend metal.

EDIT: This guy: http://forums.bit-tech.net/showthread.php?t=192623

Seems to have the ability to create his own fiberglass. But if I'm looking for sharp corners, this isn't necessary, right?

 

[CMadki4]

I agree with staticlag. Making anything from scratch, especially when working with metal, requires a variety of tooling and equipment to do properly which adds up very quickly. Not to mention it takes practice and skill to use said tools and equipment properly. Otherwise, you're wasting your time and money. Not to discourage anyone who is interested in modding/case building, but it is not easy or cheap to get results like spotswood or ekuest or the like.