is there going to be a top to the case?
So far here is my design for the carputer case.
The board itself is just under 4"x6" and the hard drive is being mounted underneath. I haven't pictured a fan yet, but there will be one.
I plan on making the case out of Lexan (Polycarbonate sheet)
I made mine from Lexan. Came out great. I was concerned about heat since this enclosure is under my passenger seat but it runs very cool. Mine is a uATX though which is much larger than what you have going on. My system has 2 x 2.5 HDDs. I have one mounted on the ceiling of the enclosure and one along the side. In the case, I also have a half height 9250 AGP video card and a SATA controller since my board has no onboard controller.
I went by a local plastic shop and asked then if they had any scrap and they gave me a 2' x 4' sheet for free. It isnt expensive to begin with but I would check it out. Also, get the cement that is recommended for Polycarbonate to Polycarbonate, it works wonderfully! Good luck.
Yeh, I don't think heat will be a problem once I get a little fan in there. Space is really tight as it is a powered passenger seat, but this should fit within a couple of mm.
I picked up the polycarbonate sheet already, but I wonder if it would be better to have the local plastic shop cut it for me than to do it with my jigsaw.
Yes it will have a top, I haven't added that to the drawing yet
For cutting plastic I prefer laser cutting. Some shops can do it for you really cheaply. It is probably what the plastic shops use as well for smaller pieces.
just my $0.02
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Table saw with a 40 tooth carbide blade worked great for me! Very smooth cuts. I need to get some pics up.